Fuel cell system with interconnect

ABSTRACT

The present invention includes a fuel cell system having a plurality of adjacent electrochemical cells formed of an anode layer, a cathode layer spaced apart from the anode layer, and an electrolyte layer disposed between the anode layer and the cathode layer. The fuel cell system also includes at least one interconnect, the interconnect being structured to conduct free electrons between adjacent electrochemical cells. Each interconnect includes a primary conductor embedded within the electrolyte layer and structured to conduct the free electrons.

FIELD OF THE INVENTION

The present invention generally relates to fuel cells and, inparticular, to an interconnect for a fuel cell.

BACKGROUND

Fuel cells, fuel cell systems and interconnects for fuel cells and fuelcell systems remain an area of interest. Some existing systems havevarious shortcomings, drawbacks, and disadvantages relative to certainapplications. Accordingly, there remains a need for furthercontributions in this area of technology.

SUMMARY

The present invention includes a fuel cell system having an interconnectthat reduces or eliminates diffusion (leakage) of fuel and oxidant byproviding an increased diffusion distance and reduced diffusion flowarea.

BRIEF DESCRIPTION OF THE DRAWINGS

The description herein makes reference to the accompanying drawingswherein like reference numerals refer to like parts throughout theseveral views, and wherein:

FIG. 1 schematically depicts some aspects of a non-limiting example of afuel cell system in accordance with an embodiment of the presentinvention.

FIG. 2 schematically depicts some aspects of a non-limiting example of across section of a fuel cell system in accordance with an embodiment ofthe present invention.

FIG. 3 is an enlarged cross sectional view of a portion of theinterconnect of FIG. 2.

FIGS. 4A and 4B depict some alternate embodiments of interconnectconfigurations.

FIG. 5 depicts a hypothetical interconnect that is contrasted hereinwith embodiments of the present invention.

FIGS. 6A and 6B show a top view and a side view, respectively, of someaspects of a non-limiting example of yet another embodiment of aninterconnect.

FIG. 7 schematically depicts some aspects of a non-limiting example of across section of a fuel cell system having a ceramic seal in accordancewith an embodiment of the present invention.

FIG. 8 schematically depicts some aspects of a non-limiting example of across section of another embodiment of a fuel cell system having aceramic seal.

FIG. 9 schematically depicts some aspects of a non-limiting example of across section of yet another embodiment of a fuel cell system having aceramic seal.

FIG. 10 schematically depicts some aspects of a non-limiting example ofa cross section of an embodiment of the present invention having achemical barrier.

FIG. 11 schematically depicts some aspects of a non-limiting example ofa cross section of an embodiment of the present invention having achemical barrier.

FIG. 12 schematically depicts some aspects of a non-limiting example ofa cross section of an embodiment of the present invention having achemical barrier and a ceramic seal.

FIG. 13 schematically depicts some aspects of a non-limiting example ofa cross section of an embodiment of the present invention having achemical barrier and a ceramic seal.

FIG. 14 schematically depicts some aspects of a non-limiting example ofa cross section of an embodiment of the present invention having achemical barrier.

FIG. 15 schematically depicts some aspects of a non-limiting example ofa cross section of an embodiment of the present invention having achemical barrier.

FIG. 16 schematically depicts some aspects of a non-limiting example ofa cross section of an embodiment of the present invention having achemical barrier, a ceramic seal, and a gap between a cathode conductorfilm and an electrolyte layer.

FIG. 17 schematically depicts some aspects of a non-limiting example ofa cross section of an embodiment of the present invention having achemical barrier, a ceramic seal, and a gap between an interconnectauxiliary conductor and an electrolyte layer.

FIG. 18 schematically depicts some aspects of a non-limiting example ofa cross section of an embodiment of the present invention having achemical barrier, a ceramic seal, and an insulator between a cathodeconductor film and an electrolyte layer.

FIG. 19 schematically depicts some aspects of a non-limiting example ofa cross section of an embodiment of the present invention having achemical barrier, a ceramic seal, and an insulator between aninterconnect auxiliary conductor and an electrolyte layer.

DETAILED DESCRIPTION

For purposes of promoting an understanding of the principles of theinvention, reference will now be made to the embodiments illustrated inthe drawings, and specific language will be used to describe the same.It will nonetheless be understood that no limitation of the scope of theinvention is intended by the illustration and description of certainembodiments of the invention. In addition, any alterations and/ormodifications of the illustrated and/or described embodiment(s) arecontemplated as being within the scope of the present invention.Further, any other applications of the principles of the invention, asillustrated and/or described herein, as would normally occur to oneskilled in the art to which the invention pertains, are contemplated asbeing within the scope of the present invention.

Referring to the drawings, and in particular FIG. 1, some aspects of anon-limiting example of a fuel cell system 10 in accordance with anembodiment of the present invention is schematically depicted. In theembodiment of FIG. 1, various features, components andinterrelationships therebetween of aspects of an embodiment of thepresent invention are depicted. However, the present invention is notlimited to the particular embodiment of FIG. 1 and the components,features and interrelationships therebetween as are illustrated in FIG.1 and described herein.

The present embodiment of fuel cell system 10 includes a plurality ofelectrochemical cells 12, i.e., individual fuel cells, formed on asubstrate 14. Electrochemical cells 12 are coupled together in series byinterconnects 16. Fuel cell system 10 is a segmented-in-seriesarrangement deposited on a flat porous ceramic tube, although it will beunderstood that the present invention is equally applicable tosegmented-in-series arrangements on other substrates, such on a circularporous ceramic tube. In various embodiments, fuel cell system 10 may bean integrated planar fuel cell system or a tubular fuel cell system.

Each electrochemical cell 12 of the present embodiment has an oxidantside 18 and a fuel side 20. The oxidant is typically air, but could alsobe pure oxygen (O₂) or other oxidants, e.g., including dilute air forfuel cell systems having air recycle loops, and is supplied toelectrochemical cells 12 from oxidant side 18. Substrate 14 of thepresent embodiment is porous, e.g., a porous ceramic material which isstable at fuel cell operation conditions and chemically compatible withother fuel cell materials. In other embodiments, substrate 14 may be asurface-modified material, e.g., a porous ceramic material having acoating or other surface modification, e.g., configured to prevent orreduce interaction between electrochemical cell 12 layers and substrate14. A fuel, such as a reformed hydrocarbon fuel, e.g., synthesis gas, issupplied to electrochemical cells 12 from fuel side 20 via channels (notshown) in porous substrate 14. Although air and synthesis gas reformedfrom a hydrocarbon fuel are employed in the present embodiment, it willbe understood that electrochemical cells using other oxidants and fuelsmay be employed without departing from the scope of the presentinvention, e.g., pure hydrogen and pure oxygen. In addition, althoughfuel is supplied to electrochemical cells 12 via substrate 14 in thepresent embodiment, it will be understood that in other embodiments ofthe present invention, the oxidant may be supplied to theelectrochemical cells via a porous substrate.

Referring to FIG. 2, some aspects of a non-limiting example of fuel cellsystem 10 are described in greater detail. Fuel cell system 10 can beformed of a plurality of layers screen printed onto substrate 14. Screenprinting is a process whereby a woven mesh has openings through whichthe fuel cell layers are deposited onto substrate 14. The openings ofthe screen determine the length and width of the printed layers. Screenmesh, wire diameter, ink solids loading and ink rheology determine thethickness of the printed layers. Fuel cell system 10 layers include ananode conductive layer 22, an anode layer 24, an electrolyte layer 26, acathode layer 28 and a cathode conductive layer 30. In one form,electrolyte layer 26 is formed of an electrolyte sub-layer 26A and anelectrolyte sub-layer 26B. In other embodiments, electrolyte layer 26may be formed of any number of sub-layers. It will be understood thatFIG. 2 is not to scale; for example, vertical dimensions are exaggeratedfor purposes of clarity of illustration.

Interconnects for solid oxide fuel cells (SOFC) are preferablyelectrically conductive in order to transport electrons from oneelectrochemical cell to another; mechanically and chemically stableunder both oxidizing and reducing environments during fuel celloperation; and nonporous, in order to prevent diffusion of the fueland/or oxidant through the interconnect. If the interconnect is porous,fuel may diffuse to the oxidant side and burn, resulting in local hotspots that may result in a reduction of fuel cell life, e.g., due todegradation of materials and mechanical failure, as well as reducedefficiency of the fuel cell system. Similarly, the oxidant may diffuseto the fuel side, resulting in burning of the fuel. Severe interconnectleakage may significantly reduce the fuel utilization and performance ofthe fuel cell, or cause catastrophic failure of fuel cells or stacks.

For segmented-in-series cells, fuel cell components may be formed bydepositing thin films on a porous ceramic substrate, e.g., substrate 14.In one form, the films are deposited via a screen printing process,including the interconnect. In other embodiments, other process may beemployed to deposit or otherwise form the thin films onto the substrate.The thickness of interconnect layer may be 5 to 30 microns, but can alsobe much thicker, e.g., 100 microns. If the interconnect is not fullynonporous, e.g., due to sintering porosity, microcracks, voids and otherdefects introduced during processing, gas or air flux throughinterconnect layer may be very high, resulting in undesirable effects,as mentioned above. Accordingly, in one aspect of the present invention,the interconnect (interconnect 16) is configured to minimize oreliminate diffusion of the oxidant and fuel therethrough.

The material of interconnect 16 of the present embodiment is a preciousmetal, such as Ag, Pd, Au and/or Pt and/or alloys thereof, althoughother materials may be employed without departing from the scope of thepresent invention. For example, in other embodiments, it isalternatively contemplated that other materials may be employed,including precious metal alloys, such as Ag—Pd, Ag—Au, Ag—Pt, Au—Pd,Au—Pt, Pt—Pd, Ag—Au—Pd, Ag—Au—Pt, Ag—Au—Pd—Pt and/or binary, ternary,quaternary alloys in the Pt—Pd—Au-Ag family, inclusive of alloys havingminor non-precious metal additions, cermets composed of a preciousmetal, precious metal alloy, Ni metal and/or Ni alloy and an inertceramic phase, such as alumina, or ceramic phase with minimum ionicconductivity which will not create significant parasitics, such as YSZ(yttria stabilized zirconia, also known as yttria doped zirconia, yttriadoping is 3-8 mol %, preferably 3-5 mol %), ScSZ (scandia stabilizedzirconia, scandia doping is 4-10 mol %, preferably 4-6 mol %), and/orconductive ceramics, such as conductive perovskites with A or B-sitesubstitutions or doping to achieve adequate phase stability and/orsufficient conductivity as an interconnect, e.g., including at least oneof LNF (LaNi_(x)Fe_(1-x)O₃, preferably x=0.6), LSM (La_(1-x)Sr_(x)MnO₃,x=0.1 to 0.3), doped ceria, doped strontium titanate (such asLa_(x)Sr_(1-x)TiO_(3-δ), x=0.1 to 0.3) LSCM(La_(1-x)Sr_(x)Cr_(1-y)Mn_(y)O₃, x=0.1 to 0.3 and y=0.25 to 0.75), dopedyttrium chromites (such as Y_(1-x)Ca_(x)CrO_(3-δ), x=0.1-0.3) and/orother doped lanthanum chromites (such as La_(1-x)Ca_(x)CrO_(3-δ),x=0.15-0.3), and conductive ceramics, such as at least one of LNF(LaNi_(x)Fe_(1-x)O₃, preferably x=0.6), LSM (La_(1-x)Sr_(x)MnO₃, x=0.1to 0.3), doped strontium titanate, doped yttrium chromites, LSCM(La_(1-x)Sr_(x)Cr_(1-y)Mn_(y)O₃), and other doped lanthanum chromites.In some embodiments, it is contemplated that all or part of interconnect16 may be formed of a Ni metal cermet and/or a Ni alloy cermet inaddition to or in place of the materials mentioned above. The Ni metalcermet and/or the Ni alloy cermet may have one or more ceramic phases,for example and without limitation, a ceramic phase being YSZ (yttriadoping is 3-8 mol %, preferably 3-5 mol %), alumina, ScSZ (scandiadoping is 4-10 mol %, preferably 4-6 mol %), doped ceria and/or TiO₂.

One example of materials for interconnect 16 isy(Pd_(x)Pt_(1-x))-(1-y)YSZ. Where x is from 0 to 1 in weight ratio,preferably x is in the range of 0 to 0.5 for lower hydrogen flux. Y isfrom 0.35 to 0.80 in volume ratio, preferably y is in the range of 0.4to 0.6.

Anode conductive layer 22 of the present embodiment is an electrodeconductive layer formed of a nickel cermet, such as such as Ni-YSZ(yttria doping in zirconia is 3-8 mol %,), Ni-ScSZ (scandia doping is4-10 mol %, preferably second doping for phase stability for 10 mol %scandia-ZrO₂) and/or Ni-doped ceria (such as Gd or Sm doping), dopedlanthanum chromite (such as Ca doping on A site and Zn doping on Bsite), doped strontium titanate (such as La doping on A site and Mndoping on B site) and/or La_(1-x)Sr_(x)Mn_(y)Cr_(1-y)O₃. Alternatively,it is considered that other materials for anode conductive layer 22 maybe employed such as cermets based in part or whole on precious metal.Precious metals in the cermet may include, for example, Pt, Pd, Au, Ag,and/or alloys thereof. The ceramic phase may include, for example, aninactive non-electrically conductive phase, including, for example, YSZ,ScSZ and/or one or more other inactive phases, e.g., having desiredcoefficients of thermal expansion (CTE) in order to control the CTE ofthe layer to match the CTE of the substrate and electrolyte. In someembodiments, the ceramic phase may include Al₂O₃ and/or a spinel such asNiAl₂O₄, MgAl₂O₄, MgCr₂O₄, NiCr₂O₄. In other embodiments, the ceramicphase may be electrically conductive, e.g., doped lanthanum chromite,doped strontium titanate and/or one or more forms of LaSrMnCrO.

One example of anode conductive layer material is 76.5% Pd, 8.5% Ni,15%3YSZ.

Anode 24 may be formed of xNiO-(100-x)YSZ (x is from 55 to 75 in weightratio), yNiO-(100-y)ScSZ (y is from 55 to 75 in weight ratio),NiO-gadolinia stabilized ceria (such as 55 wt % NiO-45 wt % GDC) and/orNiO samaria stabilized ceria in the present embodiment, although othermaterials may be employed without departing from the scope of thepresent invention. For example, it is alternatively considered thatanode layer 24 may be made of doped strontium titanate, andLa_(1-x)Sr_(x)Mn_(y)Cr_(1-y)O₃. (such asLa_(0.75)Sr_(0.25)Mn_(0.5)Cr_(0.5)O₃)

Electrolyte layer 26 of the present embodiment, e.g., electrolytesub-layer 26A and/or electrolyte sub-layer 26B, may be made from aceramic material. In one form, a proton and/or oxygen ion conductingceramic, may be employed. In one form, electrolyte layer 26 is formed ofYSZ, such as 3YSZ and/or 8YSZ. In other embodiments, electrolyte layer26 may be formed of ScSZ, such as 4ScSZ, 6ScSz and/or 10ScSZ in additionto or in place of YSZ. In other embodiments, other materials may beemployed. For example, it is alternatively considered that electrolytelayer 26 may be made of doped ceria and/or doped lanthanum gallate. Inany event, electrolyte layer 26 is essentially impervious to diffusiontherethrough of the fluids used by fuel cell 10, e.g., synthesis gas orpure hydrogen as fuel, as well as, e.g., air or O₂ as an oxidant, butallows diffusion of oxygen ions or protons.

Cathode layer 28 may be formed at least one of LSM (La_(1-x)Sr_(x)MnO₃,x=0.1 to 0.3), La_(1-x)Sr_(x)FeO₃, (such as x=0.3),La_(1-x)Sr_(x)Co_(y)Fe_(1-y)O₃ (such asLa_(0.8)Sr_(0.4)Co_(0.2)Fe_(0.8)O₃) and/or Pr_(1-x)Sr_(x)MnO₃ (such asPr_(0.8)Sr_(0.2)MnO₃), although other materials may be employed withoutdeparting from the scope of the present invention. For example, it isalternatively considered that Ruddlesden-Popper nickelates andLa_(1-x)Ca_(x)MnO₃ (such as La_(0.8)Ca_(0.2)MnO₃) materials may beemployed.

Cathode conductive layer 30 is an electrode conductive layer formed of aconductive ceramic, for example, at least one of LaNi_(x)Fe_(1-x)O₃(such as LaNi_(0.8)Fe_(0.4)O₃), La_(1-x)Sr_(x)MnO₃ (such asLa_(0.75)Sr_(0.25)MnO₃), doped lanthanum chromites (such asLa_(1-x)Ca_(x)CrO_(3-δ), x=0.15-0.3), and/or Pr_(1-x)Sr_(x)CoO₃, such asPr_(0.8)Sr_(0.2)CoO₃. In other embodiments, cathode conductive layer 30may be formed of other materials, e.g., a precious metal cermet,although other materials may be employed without departing from thescope of the present invention. The precious metals in the preciousmetal cermet may include, for example, Pt, Pd, Au, Ag and/or alloysthereof. The ceramic phase may include, for example, YSZ, ScSZ andAl₂O₃, or other ceramic materials.

One example of cathode conductive layer materials is 80 wt % Pd-20 wt %LSM.

In the embodiment of FIG. 2, various features, components andinterrelationships therebetween of aspects of an embodiment of thepresent invention are depicted. However, the present invention is notlimited to the particular embodiment of FIG. 2 and the components,features and interrelationships therebetween as are illustrated in FIG.2 and described herein.

In the present embodiment, anode conductive layer 22 is printed directlyonto substrate 14, as is a portion of electrolyte sub-layer 26A. Anodelayer 24 is printed onto anode conductive layer 22. Portions ofelectrolyte layer 26 are printed onto anode layer 24, and portions ofelectrolyte layer 26 are printed onto anode conductive layer 22 and ontosubstrate 14. Cathode layer 28 is printed on top of electrolyte layer26. Portions of cathode conductive layer 30 are printed onto cathodelayer 28 and onto electrolyte layer 26. Cathode layer 28 is spaced apartfrom anode layer 24 in a direction 32 by the local thickness ofelectrolyte layer 26.

Anode layer 24 includes anode gaps 34, which extend in a direction 36.Cathode layer 28 includes cathode gaps 38, which also extend indirection 36. In the present embodiment, direction 36 is substantiallyperpendicular to direction 32, although the present invention is not solimited. Gaps 34 separate anode layer 24 into a plurality of individualanodes 40, one for each electrochemical cell 12. Gaps 38 separatecathode layer 28 into a corresponding plurality of cathodes 42. Eachanode 40 and the corresponding cathode 42 that is spaced apart indirection 32 therefrom, in conjunction with the portion of electrolytelayer 26 disposed therebetween, form an electrochemical cell 12.

Similarly, anode conductive layer 22 and cathode conductive layer 30have respective gaps 44 and 46 separating anode conductive layer 22 andcathode conductive layer 30 into a plurality of respective anodeconductor films 48 and cathode conductor films 50. The terms, “anodeconductive layer” and “anode conductor film” may be usedinterchangeably, in as much as the latter is formed from one or morelayers of the former; and the terms, “cathode conductive layer” and“cathode conductor film” may be used interchangeably, in as much as thelatter is formed from one or more layers of the former.

In the present embodiment, anode conductive layer 22 has a thickness,i.e., as measured in direction 32, of approximately 5-15 microns,although other values may be employed without departing from the scopeof the present invention. For example, it is considered that in otherembodiments, the anode conductive layer may have a thickness in therange of 5-50 microns. In yet other embodiments, different thicknessesmay be used, depending upon the particular material and application.

Similarly, anode layer 24 has a thickness, i.e., as measured indirection 32, of approximately 5-20 microns, although other values maybe employed without departing from the scope of the present invention.For example, it is considered that in other embodiments, the anode layermay have a thickness in the range of 5-40 microns. In yet otherembodiments, different thicknesses may be used, depending upon theparticular anode material and application.

Electrolyte layer 26, including both electrolyte sub-layer 26A andelectrolyte sub-layer 26B, of the present embodiment has a thickness ofapproximately 5-15 microns with individual sub-layer thicknesses ofapproximately 5 microns minimum, although other thickness values may beemployed without departing from the scope of the present invention. Forexample, it is considered that in other embodiments, the electrolytelayer may have a thickness in the range of 5-40 microns. In yet otherembodiments, different thicknesses may be used, depending upon theparticular materials and application.

Cathode layer 28 has a thickness, i.e., as measured in direction 32, ofapproximately 10-20 microns, although other values may be employedwithout departing from the scope of the present invention. For example,it is considered that in other embodiments, the cathode layer may have athickness in the range of 10-50 microns. In yet other embodiments,different thicknesses may be used, depending upon the particular cathodematerial and application.

Cathode conductive layer 30 has a thickness, i.e., as measured indirection 32, of approximately 5-100 microns, although other values maybe employed without departing from the scope of the present invention.For example, it is considered that in other embodiments, the cathodeconductive layer may have a thickness less than or greater than therange of 5-100 microns. In yet other embodiments, different thicknessesmay be used, depending upon the particular cathode conductive layermaterial and application.

In each electrochemical cell 12, anode conductive layer 22 conducts freeelectrons away from anode 24 and conducts the electrons to cathodeconductive layer 30 via interconnect 16. Cathode conductive layer 30conducts the electrons to cathode 28.

Interconnect 16 is embedded in electrolyte layer 26, and is electricallycoupled to anode conductive layer 22, and extends in direction 32 fromanode conductive layer 22 through electrolyte sub-layer 26A towardelectrolyte sub-layer 26B, then in direction 36 from one electrochemicalcell 12 to the next adjacent electrochemical cell 12, and then indirection 32 again toward cathode conductive layer 30, to whichinterconnect 16 is electrically coupled. In particular, at least aportion of interconnect 16 is embedded within an extended portion ofelectrolyte layer 26, wherein the extended portion of electrolyte layer26 is a portion of electrolyte layer 26 that extends beyond anode 40 andcathode 42, e.g., in direction 32, and is not sandwiched between anode40 and cathode 42.

Referring to FIG. 3, some aspects of a non-limiting example ofinterconnect 16 are described in greater detail. Interconnect 16includes a blind primary conductor 52, and two blind auxiliaryconductors, or vias 54, 56. Blind primary conductor 52 is sandwichedbetween electrolyte sub-layer 26A and electrolyte sub-layer 26B, and isformed of a body 58 extending between a blind end 60 and a blind end 62opposite end 60. Blind-primary conductor 52 defines a conduction pathencased within electrolyte layer 26 and oriented along direction 36,i.e., to conduct a flow of electrons in a direction substantiallyparallel to direction 36. Blind auxiliary conductor 54 has a blind end64, and blind auxiliary conductor 56 has a blind end 66. Blind auxiliaryconductors 54 and 56 are oriented in direction 32. As that term is usedherein, “blind” relates to the conductor not extending straight throughelectrolyte layer 26 in the direction of orientation of the conductor,i.e., in the manner of a “blind hole” that ends in a structure, asopposed to a “through hole” that passes through the structure. Rather,the blind ends face portions of electrolyte layer 26. For example, end64 of conductor 54 faces portion 68 electrolyte sub-layer 26B and is notable to “see” through electrolyte sub-layer 26B. Similarly, end 66 ofconductor 56 faces portion 70 of electrolyte sub-layer 26A and is notable to “see” through electrolyte sub-layer 26A. Likewise, ends 60 and62 of body 58 face portions 72 and 74, respectively, and are not able to“see” through electrolyte sub-layer 26A.

In the embodiment of FIG. 3, various features, components andinterrelationships therebetween of aspects of an embodiment of thepresent invention are depicted. However, the present invention is notlimited to the particular embodiment of FIG. 3 and the components,features and interrelationships therebetween as are illustrated in FIG.3 and described herein. It will be understood that FIG. 3 is not toscale; for example, vertical dimensions are exaggerated for purposes ofclarity of illustration.

In the present embodiment, blind primary conductor 52 is a conductivefilm created with a screen printing process, which is embedded withinelectrolyte layer 26, sandwiched between electrolyte sub-layers 26A and26B. Anode layer 24 is oriented along a first plane, cathode layer 28 isoriented along a second plane substantially parallel to the first plane,electrolyte layer 26 is oriented along a third plane substantiallyparallel to the first plane, and the conductive film forming blindprimary conductor 52 extends in a direction substantially parallel tothe first plane.

In one form, the material of blind primary conductor 52 may be aprecious metal cermet or an electrically conductive ceramic. In otherembodiments, other materials may be employed in addition to or in placeof a precious metal cermet or an electrically conductive ceramic, e.g.,a precious metal, such as Ag, Pd, Au and/or Pt, although other materialsmay be employed without departing from the scope of the presentinvention. In various embodiments, it is contemplated that one or moreof many materials may be employed, including precious metal alloys, suchas Ag—Pd, Ag—Au, Ag—Pt, Au—Pd, Au—Pt, Pt—Pd, Ag—Au—Pd, Ag—Au—Pt, andAg—Au—Pd—Pt, cermets composed of precious metal or alloys, Ni metaland/or Ni alloy, and an inert ceramic phase, such as alumina, or ceramicphase with minimum ionic conductivity which will not generatesignificant parasitic current, such as YSZ, ScSZ, and/or conductiveceramics, such as at least one of LNF (LaNi_(x)Fe_(1-x)O₃), LSM(La_(1-x)Sr_(x)MnO₃), doped strontium titanate, doped yttrium chromites,LSCM (La_(1-x)Sr_(x)Cr_(1-y)Mn_(y)O₃), and/or other doped lanthanumchromites, and conductive ceramics, such as LNF (LaNi_(x)Fe_(1-x)O₃),for example, LaNi_(0.6)Fe_(0.4)O₃, LSM (La_(1-x)Sr_(x)MnO₃), such asLa_(0.75)Sr_(0.25)MnO₃, doped strontium titanate, doped yttriumchromites, LSCM (La_(1-x)Sr_(x)Cr_(1-y)Mn_(y)O₃), such asLa_(0.75)Sr_(0.25)Cr_(0.5)Mn_(0.5)O₃, and other doped lanthanumchromites. In other embodiments, it is contemplated that blind primaryconductor 52 may be formed of a Ni metal cermet and/or a Ni alloy cermetin addition to or in place of the materials mentioned above. The Nimetal cermet and/or the Ni alloy cermet may have one or more ceramicphases, for example and without limitation, a ceramic phase being YSZ,alumina, ScSZ, doped ceria and/or TiO₂. In various embodiments, blindprimary conductor 52 may be formed of materials set forth above withrespect to interconnect 16.

One example of materials for blind primary conductor 52 isy(Pd_(x)Pt_(1-x))-(1-y)YSZ. Where x is from 0 to 1 in weight ratio. Forcost reduction, x is preferred in the range of 0.5 to 1. For betterperformance and higher system efficiency, x is preferred in the range of0 to 0.5. Because hydrogen has higher flux in Pd. Y is from 0.35 to 0.80in volume ratio, preferably y is in the range of 0.4 to 0.6.

Another example of materials for blind primary conductor 52 is x % Pd-y% Ni-(100-x-y) % YSZ, where x=70-80, y=5-10.

Each of blind auxiliary conductors 54 and 56 may be formed from the sameor different materials than primary conductor 52. In one form, blindauxiliary conductor 54 is formed during processing of blind primaryconductor 52 and from the same material as blind primary conductor 52,whereas blind auxiliary conductor 56 is formed at the same process stepas cathode conductive layer 30 and from the same material as cathodeconductive layer 30. However, in other embodiments, blind primaryconductor 52, blind auxiliary conductor 54 and blind auxiliary conductor56 may be made from other material combinations without departing fromthe scope of the present invention.

The materials used for blind auxiliary conductor 54 and blind auxiliaryconductor 56 may vary with the particular application. For example, withsome material combinations, material migration may occur at theinterface of interconnect 16 with anode conductive layer 22 and/orcathode conductive layer 30 during either cell fabrication or celltesting, which may cause increased resistance at the interface andhigher cell degradation during fuel cell operation. Material may migrateinto primary conductor 52 from anode conductive layer 22 and/or cathodeconductive layer 30, and/or material may migrate from primary conductor52 into anode conductive layer 22 and/or cathode conductive layer 30,depending upon the compositions of primary conductor 52, anodeconductive layer 22 and cathode conductive layer 30. To reduce materialmigration at the interconnect/conductive layer interface, one or both ofblind auxiliary conductor 54 and blind auxiliary conductor 56 may beformed from a material that yields an electrically conductive chemicalbarrier layer between primary conductor 52 and a respective one or bothof anode conductive layer 22 (anode conductor film 48) and/or cathodeconductive layer 30 (cathode conductor film 50). This chemical barriermay eliminate or reduce material migration during fuel cell fabricationand operation.

Materials for auxiliary conductor 54 at the interconnect 16 and anodeconductive layer 22 interface that may be used to form a chemicalbarrier may include, but are not limited to Ni cermet, Ni-precious metalcermet and the precious metal can be Ag, Au, Pd, Pt, or the alloy ofthem, the ceramic phase in the cermet can be at least one of YSZ (yttriadoping is 3-5 mol % in zironia), ScSZ (scandia doping is 4-6 mol % inzirconia), doped ceria (such as GDC, or SDC), alumina, and TiO₂, orconductive ceramics, such as doped strontium titanate, doped yttriumchromites, La_(1-x)Sr_(x)Cr_(1-y)Mn_(y)O₃ (x=0.15-0.35, y=0.25-0.5), andother doped lanthanum chromites.

One example of auxiliary conductor 54 is 50v % (50Pd50Pt)-50v %3YSZ.

Another example of auxiliary conductor 54 is 15% Pd, 19% NiO, 66% NTZ,where NTZ is 73.6 wt % NiO, 20.0% TiO₂, 6.4% 3YSZ.

Materials for auxiliary conductor 56 at the interconnect 16 and cathodeconductive layer 30 interface that may be used to form a chemicalbarrier may include, but are not limited to precious metal cermetshaving a precious metal being at least one of: Ag, Au, Pd, Pt, or itsalloy, wherein the ceramic phase may be at least one of YSZ (yttriadoping is preferred from 3-5 mol %), ScSZ (scandia doping is preferredfrom 4-6 mol %), LNF (LaNi_(x)Fe_(1-x)O₃, x=0.6), LSM(La_(1-x)Sr_(x)MnO₃, x=0.1 to 0.3), doped yttrium chromites (such asY_(0.8)Ca_(0.2)CrO₃), LSCM (La_(1-x)Sr_(x)Cr_(1-y)Mn_(y)O₃),x=0.15-0.35, y=0.5-0.75), and other doped lanthanum chromites (such asLa_(0.7)Ca_(0.3)CrO₃), or conductive ceramics, such as at least one ofLNF (LaNi_(x)Fe_(1-x)O₃), LSM (La_(1-x)Sr_(x)MnO₃), Ruddlesden-Poppernickelates, LSF (such as La_(0.8)Sr_(0.2)FeO₃), LSCF(La_(0.6)Sr_(0.4)Co_(0.2)Fe_(0.8)O₃), LSCM(La_(1-x)Sr_(x)Cr_(1-y)Mn_(y)O₃), LCM (such as La_(0.8)Ca_(0.2)MnO₃),doped yttrium chromites and other doped lanthanum chromites.

One example for auxiliary conductor 56 is 50v % (50Pd50Pt)-50v %3YSZ.

Another example of auxiliary conductor 56 is 15% Pd, 19% NiO, 66% NTZ,where NTZ is 73.6 wt % NiO, 20.0% TiO₂, 6.4% 3YSZ.

In the present embodiment, auxiliary conductor 54 has a width 76, i.e.,in direction 36, of approximately 0.4 mm, although greater or lesserwidths may be used without departing from the scope of the presentinvention. Similarly, auxiliary conductor 56 has a width 78, i.e., indirection 36, of approximately 0.4 mm, although greater or lesser widthsmay be used without departing from the scope of the present invention.Primary conductor 52 has a length in direction 36 that defines a minimumdiffusion distance 80 for any hydrogen that may diffuse throughinterconnect 16, e.g., due to sintering porosity, microcracks, voidsand/or other defects introduced into interconnect 16 during processing.In the present embodiment, diffusion distance 80 is 0.6 mm, althoughgreater or lesser widths may be used without departing from the scope ofthe present invention. The film thickness 82 of primary conductor 52,i.e., as measured in direction 32, is approximately 5-15 microns. Thetotal height 84 of interconnect 16 in direction 32 is approximately10-25 microns, which generally corresponds to the thickness ofelectrolyte layer 26.

The total diffusion distance for hydrogen diffusing through interconnect16 may include the height of auxiliary conductor 54 and auxiliaryconductor 56 in direction 32, which may be given by subtracting from thetotal height 84 the film thickness 82 of primary conductor 52, whichyields approximately 10 microns. Thus, the diffusion distance ispredominantly controlled by diffusion distance 80, e.g., since theheights of auxiliary conductors 54 and 56 represent only a smallfraction of the total diffusion distance.

Referring to FIGS. 4A and 4B, a plan view of a continuous “strip”configuration of interconnect 16 and a plan view of a “via”configuration of interconnect 16 are respectively depicted. The term,“strip,” pertains to the configuration being in the form of a singlelong conductor that is comparatively narrow in width as compared tolength. In the strip configuration, the primary conductor takes the formof a continuous strip 52A extending in a direction 86 that in thepresent embodiment is substantially perpendicular to both directions 32and 36, and runs approximately the length in direction 86 ofelectrochemical cell 12. In the depiction of FIGS. 4A and 4B, direction32 extends into and out of the plane of the drawing, and hence isrepresented by an “X” within a circle. The term, “via,” pertains to arelatively small conductive pathway through a material that connectselectrical components. In the depiction of FIG. 4B, the primaryconductor takes the form of a plurality of vias 52B, e.g., each having awidth in direction 86 of only approximately 0.4 mm, although greater orlesser widths may be used without departing from the scope of thepresent invention.

In the embodiment of FIGS. 4A and 4B, various features, components andinterrelationships therebetween of aspects of an embodiment of thepresent invention are depicted. However, the present invention is notlimited to the particular embodiment of FIGS. 4A and 4B and thecomponents, features and interrelationships therebetween as areillustrated in FIGS. 4A and 4B and described herein.

Referring again to FIG. 3, in conjunction with FIGS. 4A and 4B, theminimum diffusion area of interconnect 16 is controlled by the diffusionarea of primary conductor 52, which serves as a diffusion flow orificethat restricts the diffusion of fluid. For example, if, for any reason,primary conductor 52 is not non-porous, fluid, e.g., oxidant and fuel inliquid and/or gaseous form may diffuse through interconnect 16. Suchdiffusion is controlled, in part, by the film thickness 82. In the“strip” configuration, the diffusion area is given by the width ofcontinuous strip 52A in direction 86 times the film thickness 82,whereas in the “via” configuration, the diffusion area is given by thewidth of each via 52B in direction 86 times the film thickness 82 timesthe number of vias 52B.

Although it may be possible to employ an interconnect that extends onlyin direction 32 from anode conductor film 48 to cathode conductor film50 (assuming that cathode conductor film 50 were positioned above anodeconductor films 48 in direction 36), such a scheme would result inhigher leakage than were the interconnect of the present inventionemployed.

For example, referring to FIG. 5, some aspects of a non-limiting exampleof an interconnect 88 are depicted, wherein interconnect 88 in the formof a via passing through an electrolyte layer 90, which is clearly notembedded in electrolyte layer 90 or sandwiched between sub-layers ofelectrolyte layer 90, and does not include any blind conductors.Interconnect 88 transfers electrical power from an anode conductor 92 toa cathode conductor 94. For purposes of comparison, the length 96 ofinterconnect 88 in direction 32, which corresponds to the thickness ofelectrolyte layer 90, is assumed to be the 10-15 microns, e.g., similarto interconnect 16, and the width of interconnect 88, e.g., the width ofthe open slot in the electrolyte 96 into which interconnect 88 isprinted, in direction 36 is assumed to be the minimum printable viadimension 98 in direction 36 with current industry technology, which isapproximately 0.25 mm. The length of interconnect 88 in direction 86 isassumed to be 0.4 mm. Thus, with interconnect 88, the diffusion flowarea for one via is approximately 0.25 mm times 0.4 mm, which equals 0.1mm². The limiting dimension is the minimum 0.25 mm screen printed viadimension 98.

With the present invention, however, assuming via 52B (FIG. 4B) to havethe same length in direction 86 of 0.4 mm, the diffusion flow area forone via of 0.4 mm times the film thickness in direction 32 of 0.010 mm(10 microns) equals 0.004 mm², which is only 4 percent of the flow areaof interconnect 88. Thus, by employing a geometry that allows areduction of the minimum dimension that limits a minimum diffusion flowarea, the diffusion flow area of the interconnect may be reduced,thereby potentially decreasing diffusion of oxidant and/or fuel throughthe interconnector, e.g., in the event the interconnect is not fullynon-porous (such as, for example, due to process limitations and/ormanufacturing defects), or the interconnect is a mixed ion andelectronic conductor.

Further, the diffusion distance in interconnect 88 corresponds to thethickness 96 of interconnect 88, which in the depicted example is alsothe thickness of electrolyte layer 90, i.e., 10-15 microns.

In contrast, the diffusion distance of the inventive blind primaryconnector 52, whether in the form of a continuous strip 52A or a via52B, is diffusion distance 80, which is 0.6 mm, and which is 40-60 timesthe diffusion distance of interconnect 88 (0.6 mm divided by 10-15microns), which is many times the thickness of the electrolyte. Thus, byemploying a geometry wherein the diffusion distance extends in adirection not limited by the thickness of the electrolyte, the diffusiondistance of the interconnect may be substantially increased, therebypotentially decreasing diffusion of oxidant and/or fuel through theinterconnector.

Generally, the flow of fuel and/or air through an interconnect made froma given material and microstructure depends on the flow area and flowdistance. Some embodiments of the present invention may reduce fueland/or air flow through the interconnect by 10² to 10⁴ magnitude, e.g.,if the connector is not non-porous, depending on the specific dimensionof the interconnect used.

For example, processing-related defects such as sintering porosity,microcracks and voids are typically from sub-microns to a few microns insize (voids) or a few microns to 10 microns (microcracks). With adiffusion distance of only 10-15 microns, the presence of a defect mayprovide a direct flowpath through the interconnect, or at least decreasethe diffusion distance by a substantial percentage. For example, assumea design diffusion distance of 10 microns. In the presence of a 10micron defect, a direct flowpath for the flow of hydrogen and/or oxidantwould occur, since such a defect would open a direct pathway through theinterconnect (it is noted that the anode/conductive layer andcathode/conductive layer are intentionally porous). Even assuming adesign diffusion distance of 15 microns in the presence of a 10 microndefect, the diffusion distance would be reduced by 67%, leaving a netdiffusion distance of only 5 microns.

On the other hand, a 10 micron defect in the inventive interconnect 16would have only negligible effect on the 0.6 mm design diffusiondistance of primary conductor 52, i.e., reducing the 0.6 mm designdiffusion distance to 0.59 mm, which is a relatively inconsequentialreduction caused by the presence of the defect.

Referring to FIGS. 6A and 6B, some aspects of a non-limiting example ofan embodiment of the present invention having a blind primary conductorin the form of a via 52C extending in direction 86 are depicted. In thedepiction of FIG. 6A, direction 32 extends into and out of the plane ofthe drawing, and hence is represented by an “X” within a circle. In thedepiction of FIG. 6B, direction 36 extends into and out of the plane ofthe drawing, and hence is represented by an “X” within a circle. Via 52Cis similar to via 52B, except that it extends in direction 86 ratherthan direction 36, for example, as indicated by diffusion distance 80being oriented in direction 86. It will be understood that althoughFIGS. 6A and 6B depict only a single via 52C, embodiments of the presentinvention may include a plurality of such vias extending along direction86.

The direction of electron flow in FIGS. 6A and 6B is illustrated bythree dimensional flowpath line 100. Electrons flow in direction 36through anode conductor film 48 toward auxiliary conductor 54, and thenflow in direction 32 through auxiliary conductor 54 toward via 52C. Theelectrons then flow in direction 86 through via 52C toward auxiliaryconductor 56, and then flow in direction 32 through auxiliary conductor56 into cathode conductor film 50, after which the electrons flow indirection 36 through cathode conductor film 50, e.g., to the nextelectrochemical cell.

In the embodiment of FIGS. 6A and 6B, various features, components andinterrelationships therebetween of aspects of an embodiment of thepresent invention are depicted. However, the present invention is notlimited to the particular embodiment of FIGS. 6A and 6B and thecomponents, features and interrelationships therebetween as areillustrated in FIGS. 6A and 6B and described herein.

Referring to FIG. 7, some aspects of a non-limiting example of anembodiment of a fuel cell system 210 are schematically depicted. Fuelcell system 210 includes a plurality of electrochemical cells 212disposed on a substrate 214, each electrochemical cell 212 having a sealin the form of a ceramic seal 102. Fuel cell system 210 also includesthe components set forth above and described with respect to fuel cellsystem 10, e.g., including interconnects 16 having blind primaryconductors 52 and blind auxiliary conductors or vias 54 and 56; anoxidant side 18; a fuel side 20; electrolyte layers 26; anodes 40;cathodes 42, anode conductor films 48 and cathode conductor films 50.The description of substrate 14 applies equally to substrate 214. In theembodiment of FIG. 7, auxiliary conductor 56 of interconnect 16 isformed of the same material as cathode conductor film 50, whereasauxiliary conductor 54 of interconnect 16 is formed of the same materialas anode conductor film 48. Blind primary conductor 52 of interconnect16 is formed of the same material described above with respect tointerconnect 16 in the embodiment of FIG. 2. In other embodiments, forexample, auxiliary conductor 54 and/or auxiliary conductor 56 may beformed of the same material as blind primary conductor 52, or may beformed of different materials. In one form, blind primary conductor 52is in the form of a continuous strip, e.g., continuous strip 52Adepicted in FIG. 4A. In another form, blind primary conductor 52 is inthe form of a plurality of vias, such as vias 52B in FIG. 4B. In otherembodiments, blind primary conductor 52 may take other forms notexplicitly set forth herein.

In one form, ceramic seal 102 is applied onto porous substrate 214, andis positioned horizontally (in the perspective of FIG. 7) between theanode conductor film 48 of one electrochemical cell 212 and theauxiliary conductor 54 of the adjacent electrochemical cell 212. Inother embodiments, ceramic seal 102 may be located in other orientationsand locations. Ceramic seal 102 has a thickness, i.e., as measured indirection 32, of approximately 5-30 microns, although other thicknessvalues may be employed in other embodiments. In one form, ceramic seal102 is impervious to gases and liquids, such as the fuel and oxidantsemployed by electrochemical cells 212, and is configured to prevent theleakage of gases and liquids from substrate 214 in those areas where itis applied. In other embodiments, ceramic seal 102 may be substantiallyimpervious to gases and liquids, and may be configured to reduce leakageof gases and liquids from substrate 214 in those areas where it isapplied, e.g., relative to other configurations that do not employ aceramic seal. Ceramic seal 102 is configured to provide an essentially“gas-tight” seal between substrate 214 and fuel cell components disposedon the side of ceramic seal 102 opposite of that of substrate 214.

In one form, ceramic seal 102 is positioned to prevent or reduce leakageof gases and liquids from substrate 214 into interconnect 16. In oneform, ceramic seal 102 extends in direction 36, and is positionedvertically (in direction 32) between porous substrate 214 on the bottomand blind primary conductor 52 of interconnect 16 and electrolyte 26 onthe top, thereby preventing the leakages of gases and liquids into theportions of blind primary conductor 52 (and electrolyte 26) that areoverlapped by ceramic seal 102. In other embodiments, ceramic seal 102may be disposed in other suitable locations in addition to or in placeof that illustrated in FIG. 7. Blind primary conductor 52 is embeddedbetween a portion of ceramic seal 102 on the bottom and a portion ofextended electrolyte 26 on the top. The diffusion distance in theembodiment of FIG. 7 is primarily defined by the length of the overlapof interconnect 16 by both ceramic seal 102 and electrolyte 26 indirection 36. In one form, the overlap is 0.3-0.6 mm, although in otherembodiments, other values may be employed. Interconnect 16 extends intothe active electrochemical cell 212 area. In some embodiments, theprimary interconnect area of the configuration illustrated in FIG. 7 maybe smaller than other designs, which may increase the total active cellarea on substrate 214, which may increase the efficiency of fuel cellsystem 210.

Ceramic seal 102 is formed from a ceramic material. In one form, theceramic material used to form ceramic seal 102 is yittria stabilizedzirconia, such as 3YSZ. In another form, the material used to formceramic seal 102 is scandia stabilized zirconia, such as 4ScSZ. Inanother form, the material used to form ceramic seal 102 is alumina. Inanother form, the material used to form ceramic seal 102 isnon-conductive Pyrochlore materials, such as La₂Zr₂O₇. Other embodimentsmay employ other ceramics, e.g., depending upon various factors, such ascompatibility with the materials of adjacent portions of eachelectrochemical cell 212 and substrate 214, the fuels and oxidantsemployed by fuel cell system 210, and the local transient andsteady-state operating temperatures of fuel cell system 210. Still otherembodiments may employ materials other than ceramics.

In the embodiment of FIG. 7, various features, components andinterrelationships therebetween of aspects of an embodiment of thepresent invention are depicted. However, the present invention is notlimited to the particular embodiment of FIG. 7 and the components,features and interrelationships therebetween as are illustrated in FIG.7 and described herein.

Referring to FIG. 8, some aspects of a non-limiting example of anembodiment of a fuel cell system 310 are schematically depicted. Fuelcell system 310 includes a plurality of electrochemical cells 312disposed on a substrate 314, each electrochemical cell 312 including aceramic seal 102. Fuel cell system 310 also includes the components setforth above and described with respect to fuel cell system 10, e.g.,including interconnects 16 having blind primary conductors 52 and blindauxiliary conductors or vias 54 and 56; an oxidant side 18; a fuel side20; electrolyte layers 26; anodes 40; cathodes 42, anode conductor films48 and cathode conductor films 50. The description of substrate 14applies equally to substrate 314. In the embodiment of FIG. 8,interconnect 16 is formed predominantly by the material of anodeconductor film 48, and hence, blind primary conductor 52 and auxiliaryconductor 54 in the embodiment of FIG. 8 may be considered as extensionsof anode conductor film 48. For example, blind primary conductor 52 andauxiliary conductor 54 are depicted as being formed by the material ofanode conductor film 48, whereas auxiliary conductor 56 is formed of thematerials set forth above for interconnect 16 in the embodiment of FIG.2. In one form, blind primary conductor 52 is in the form of acontinuous strip, e.g., continuous strip 52A depicted in FIG. 4A. Inanother form, blind primary conductor 52 is in the form of a pluralityof vias, such as vias 52B in FIG. 4B. In other embodiments, blindprimary conductor 52 may take other forms not explicitly set forthherein.

Ceramic seal 102 is positioned to prevent or reduce leakage of gases andliquids from substrate 314 into interconnect 16. In one form, ceramicseal 102 is positioned vertically (in direction 32) between poroussubstrate 314 on the bottom and blind primary conductor 52 andelectrolyte 26 on the top, thereby preventing the leakages of gases andliquids into the portions of blind primary conductor 52 that areoverlapped by ceramic seal 102. Blind primary conductor 52 is embeddedbetween a portion of ceramic seal 102 on the bottom and extendedelectrolyte 26 on the top. The diffusion distance in the embodiment ofFIG. 8 is primarily defined by the length of the overlap of interconnect16 by both ceramic seal 102 and electrolyte 26 in direction 36. In oneform, the overlap is 0.3-0.6 mm, although in other embodiments, othervalues may be employed.

Because ceramic seal 102 prevents the ingress of gas and liquids intoelectrochemical cell 312, interconnect 16 does not need to be as dense(in order to prevent or reduce leakage) as other designs that do notinclude a seal, such as ceramic seal 102. In such designs, interconnect16 may be formed of the materials used to form anode conductor layer 48and/or cathode conductor layer 50. For example, referring to FIG. 9, anembodiment is depicted wherein interconnect 16 is formed entirely of thematerials used to form anode conductor layer 48 and cathode conductorlayer 50. FIG. 9 schematically depicts some aspects of a non-limitingexample of an embodiment of a fuel cell system 410. Fuel cell system 410includes a plurality of electrochemical cells 412 disposed on asubstrate 414, each electrochemical cell 412 including a ceramic seal102. Fuel cell system 410 also includes the components set forth aboveand described with respect to fuel cell system 10, e.g., includinginterconnects 16 having blind primary conductors 52 and blind auxiliaryconductors or vias 54 and 56; an oxidant side 18; a fuel side 20;electrolyte layers 26; anodes 40; cathodes 42, anode conductor films 48and cathode conductor films 50. The description of substrate 14 appliesequally to substrate 414. In the embodiment of FIG. 9, blind primaryconductor 52 and auxiliary conductor 54 are formed of the same materialused to form anode conductor film 48, and are formed in the same processsteps used to form anode conductor film 48. Hence, blind primaryconductor 52 and auxiliary conductor 54 in the embodiment of FIG. 9 maybe considered as extensions of anode conductor film 48. Similarly, inthe embodiment of FIG. 9, auxiliary conductor 56 is formed of the samematerial used to form cathode conductor film 50, and is formed in thesame process steps used to form cathode conductor film 50. Hence,auxiliary conductor 56 in the embodiment of FIG. 9 may be considered asan extension of cathode conductor film 50.

In the embodiments of FIGS. 8 and 9, various features, components andinterrelationships therebetween of aspects of embodiments of the presentinvention are depicted. However, the present invention is not limited tothe particular embodiments of FIGS. 8 and 9 and the components, featuresand interrelationships therebetween as are illustrated in FIGS. 8 and 9and described herein.

Referring to FIGS. 10-15 generally, the inventors have determined thatmaterial diffusion between the interconnect and adjacent components,e.g., an anode and/or an anode conductor film and/or cathode and/orcathode conductor film, may adversely affect the performance of certainfuel cell systems. Hence, some embodiments of the present inventioninclude an electrically conductive chemical barrier (e.g., as discussedabove, and/or chemical barrier 104, discussed below with respect toFIGS. 10-15) to prevent or reduce such material diffusion. In variousembodiments, chemical barrier 104 may be configured to prevent or reducematerial migration or diffusion at the interface between theinterconnect and an anode, and/or between the interconnect and an anodeconductor film, and/or between the interconnect and a cathode, and/orbetween the interconnect and a cathode conductor film which may improvethe long term durability of the interconnect. For example, without achemical barrier, material migration (diffusion) may take place at theinterface between an interconnect formed of a precious metal cermet, andan anode conductor film and/or anode formed of a Ni-based cermet. Thematerial migration may take place in both directions, e.g., Ni migratingfrom the anode conductive layer/conductor film and/or anode into theinterconnect, and precious metal migrating from the interconnect intothe conductive layer/conductor film and/or anode. The material migrationmay result in increased porosity at or near the interface between theinterconnect and the anode conductor film and/or anode, and may resultin the enrichment of one or more non or low-electronic conducting phasesat the interface, yielding a higher area specific resistance (ASR), andhence resulting in reduced fuel cell performance. Material migrationbetween the interconnect and the cathode and/or between the interconnectand the cathode conductor film may also or alternatively result indeleterious effects on fuel cell performance.

Accordingly, some embodiments employ a chemical barrier, e.g., chemicalbarrier 104, that is configured to prevent or reduce material migrationor diffusion at the interface between the interconnect and an adjacentelectrically conductive component, such as one or more of an anode, ananode conductive layer/conductor film, a cathode and/or a cathodeconductive layer/conductor film, and hence prevent or reduce materialmigration (diffusion) that might otherwise result in deleterious effect,e.g., the formation of porosity and the enrichment of one or more non orlow-electronic conducting phases at the interface. Chemical barrier 104may be formed of one or both of two classes of materials; cermet and/orconductive ceramic. For the cermet, the ceramic phase may be one or moreof an inert filler; a ceramic with low ionic conductivity, such as YSZ;and an electronic conductor. In various embodiments, e.g., for the anodeside (e.g., for use adjacent to an anode and/or anode conductivelayer/conductor film), chemical barrier 104 may be formed of one or morematerials, including, without limitation, Ni cermet or Ni-precious metalcermet. The precious metal phase may be, for example and withoutlimitation, one or more of Ag, Au, Pd, Pt, or one or more alloys of Ag,Au, Pd and/or Pt. The ceramic phase in the cermet may be, for exampleand without limitation, be at least one of YSZ (such as 3YSZ), ScSZ(such as 4ScSZ), doped ceria (such as Gd_(0.1)Ce_(0.9)O₂), SrZrO₃,pyrochlores of the composition (M_(RE))₂Zr₂O₇ (where M_(RE)=one or morerare earth cations, for example and without limitation La, Pr, Nd, Gd,Sm, Ho, Er, and/or Yb), for example and without limitation, La₂Zr₂O₇ andPr₂Zr₂O₇, alumina, and TiO₂, or one or more electronically conductiveceramics, such as doped ceria (higher electronic conductivity at loweroxygen partial pressure to provide low enough ASR due to thin film),doped strontium titanate, LSCM (La_(1-x)Sr_(x)Cr_(1-y)Mn_(y)O₃,x=0.15-0.35, y=0.25-0.5), and/or other doped lanthanum chromites anddoped yttria chromites. In various embodiments, e.g., for the cathodeside (e.g., for use adjacent to a cathode and/or cathode conductivelayer/conductor film), chemical barrier 104 may be formed of one or morematerials, including, without limitation precious metal cermet. Theprecious metal phase may be, for example and without limitation, one ormore of Ag, Au, Pd, Pt, or one or more alloys of Ag, Au, Pd and/or Pt.The ceramic phase in the cermet may be, for example and withoutlimitation, be at least one of YSZ, ScSZ, doped ceria, SrZrO₃,pyrochlores of the composition (M_(RE))₂Zr₂O₇ (where M_(RE)=one or morerare earth cations, for example and without limitation La, Pr, Nd, Gd,Sm, Ho, Er, and/or Yb), for example and without limitation, La₂Zr₂O₇ andPr₂Zr₂O₇, alumina, and TiO₂, or one or more electronically conductiveceramics, such as LNF (LaNi_(x)Fe_(1-x)O₃, such as x=0.6) LSM(La_(1-x)Sr_(x)MnO₃, x=0.15-0.3), LCM (such as La_(0.8)Ca_(0.2)MnO₃),Ruddlesden-Popper nickelates, LSF (such as La_(0.8)Sr_(0.2)FeO₃), LSCF(La_(0.6)Sr_(0.4)CO_(0.2)Fe_(0.8)O₃), LSCM(La_(1-x)Sr_(x)Cr_(1-y)Mn_(y)O₃, x=0.15-0.35, y=0.5-0.75) doped yttriumchromites, and other doped lanthanum chromites. The selection of thespecific material(s) for chemical barrier 104 may vary with the needs ofthe application, e.g., depending upon cost, ease of manufacturing, thetype of materials used for the component(s) electrically adjacent tointerconnect 16 and/or one of its subcomponents, e.g., blind primaryconductor 52, auxiliary conductor 54 and auxiliary conductor 56.

One example of anode side chemical barrier materials is 15% Pd, 19% NiO,66% NTZ, where NTZ is 73.6 wt % NiO, 20.0% TiO₂, 6.4% YSZ.

Another example of anode side chemical barrier materials is doped ceria,such as Gd_(0.1)Ce_(0.9)O₂.

Experimental testing with a chemical barrier, such as chemical barrier104, in a fuel cell system yielded approximately 0.1% per thousand hourdegradation rate in cell power output over the course of 1300 hours oftesting using a chemical barrier formed of 30 wt % Pd-70 wt % NTZ cermet(NTZ=NiO₂-3YSZ), disposed between an interconnect formed of 65Pd35Pt-YSZcermet and an anode conductive layer formed of 20 wt % Pd—Ni-spinel. Ina comparative test, but without the inclusion of a chemical barrier,such as chemical barrier 104, an interconnect formed of 50v %(96Pd6Au)-50v % YSZ cermet directly interfacing with an anode conductivelayer formed of 20 wt % Pd—Ni-spinel showed significant degradation inabout 10 hours of testing, and fuel cell failure at about 25 hours oftesting resulting from material migration between the interconnect andthe anode conductive layer. In another test, two fuel cells were testedusing a chemical barrier 104 formed of a conductive ceramic (10 mol % Gddoped CeO₂) disposed between disposed between an anode conductor filmand an interconnect. ASR for the interconnect showed no degradationafter approximately 8000 hours of testing, and instead showed slightimprovement, yielding final values of 0.05 ohm-cm² and 0.06 ohm-cm² inthe two test articles.

Referring to FIG. 10, some aspects of a non-limiting example of anembodiment of a fuel cell system 510 disposed on a substrate 514 areschematically depicted. Fuel cell system 510 includes a chemical barrier104. Fuel cell system 510 also includes some the components set forthabove and described with respect to fuel cell system 10, e.g., includingan interconnects 16 having a blind primary conductor 52; an oxidant side18; a fuel side 20; electrolyte layers 26; anodes 40; and cathodes 42.Although only a single instance of interconnect 16, blind primaryconductor 52, anode 40 and cathode 42 are depicted, and two instances ofelectrolyte layers 26 are depicted, it will be understood that fuel cellsystem 510 may include a plurality of each such components, e.g.,arranged in series in direction 36, e.g., similar to embodimentsdescribed above. The description of substrate 14 applies equally tosubstrate 514. In fuel cell system 510, chemical barrier 104 is disposedbetween anode 40 and interconnect 16 (blind primary conductor 52),extending in direction 32 between anode 40 and interconnect 16, and isconfigured to prevent material migration between anode 40 andinterconnect 16 (blind primary conductor 52). Chemical barrier 104 maybe formed from one or more of the materials set forth above with respectto the embodiments of FIGS. 10-15.

Referring to FIG. 11, some aspects of a non-limiting example of anembodiment of a fuel cell system 610 are schematically depicted. Fuelcell system 610 includes a plurality of electrochemical cells 612disposed on a substrate 614, each electrochemical cell 612 including achemical barrier 104. Fuel cell system 610 also includes the componentsset forth above and described with respect to fuel cell system 10, e.g.,including interconnects 16 having blind primary conductors 52 and blindauxiliary conductors or vias 54 and 56; an oxidant side 18; a fuel side20; electrolyte layers 26; anodes 40; cathodes 42, anode conductor films48 and cathode conductor films 50. The description of substrate 14applies equally to substrate 614. In fuel cell system 610, chemicalbarrier 104 is disposed between anode conductor film 48 and interconnect16 (blind primary conductor 52), extending in direction 32 between anodeconductor film 48 and interconnect 16, and is configured to preventmaterial migration between anode conductor film 48 and interconnect 16(blind primary conductor 52). Chemical barrier 104 may be formed fromone or more of the materials set forth above with respect to theembodiments of FIGS. 10-15. In fuel cell system 610, a portion ofelectrolyte layer 26 is disposed between anode 40 and chemical barrier104, extending in direction 36 between anode 40 and chemical barrier104.

Referring to FIG. 12, some aspects of a non-limiting example of anembodiment of a fuel cell system 710 are schematically depicted. Fuelcell system 710 includes a plurality of electrochemical cells 712disposed on a substrate 714, each electrochemical cell 712 including aceramic seal 102 and a chemical barrier 104. Fuel cell system 710 alsoincludes the components set forth above and described with respect tofuel cell system 10, e.g., including interconnects 16 having blindprimary conductors 52 and blind auxiliary conductors or vias 54 and 56;an oxidant side 18; a fuel side 20; electrolyte layers 26; anodes 40;cathodes 42, anode conductor films 48 and cathode conductor films 50.The description of substrate 14 applies equally to substrate 714. Infuel cell system 710, ceramic seal 102 is positioned to prevent orreduce leakage of gases and liquids from substrate 714 into interconnect16 (blind interconnect 52), and extends in direction 36 between theanode conductor film 48 of one electrochemical cell 712 and theauxiliary conductor 54 of an adjacent electrochemical cell 712.

In fuel cell system 710, ceramic seal 102 is positioned vertically (indirection 32) between porous substrate 714 on the bottom and blindprimary conductor 52 of interconnect 16 and electrolyte 26 on the top,thereby preventing the leakages of gases and liquids from substrate 714into the portions of blind primary conductor 52 (and electrolyte 26)that are overlapped by ceramic seal 102. In other embodiments, ceramicseal 102 may be disposed in other suitable locations in addition to orin place of that illustrated in FIG. 12. Ceramic seal 102 may be formedof one or more of the materials set forth above with respect to theembodiment of FIG. 7. A portion of blind primary conductor 52 isembedded between ceramic seal 102 on the bottom and electrolyte 26 onthe top. The diffusion distance in the embodiment of FIG. 12 isprimarily defined by the length of the overlap of blind primaryconductor 52 by both ceramic seal 102 and electrolyte 26 in direction36.

In fuel cell system 710, chemical barrier 104 is disposed between anodeconductor film 48 and interconnect 16 (blind primary conductor 52),extending in direction 32 between anode conductor film 48 and both blindprimary conductor 52 and auxiliary conductor 54 of interconnect 16, andis configured to prevent material migration between anode conductor film48 and blind primary conductor 52 and auxiliary conductor 54. Chemicalbarrier 104 may be formed from one or more of the materials set forthabove with respect to the embodiments of FIGS. 10-15.

Referring to FIG. 13, some aspects of a non-limiting example of anembodiment of a fuel cell system 810 are schematically depicted. Fuelcell system 810 includes a plurality of electrochemical cells 812disposed on a substrate 814, each electrochemical cell 812 including aceramic seal 102 and a chemical barrier 104. Fuel cell system 810 alsoincludes the components set forth above and described with respect tofuel cell system 10, e.g., including interconnects 16 having blindprimary conductors 52 and auxiliary conductors or vias 54 and 56; anoxidant side 18; a fuel side 20; electrolyte layers 26; anodes 40;cathodes 42, anode conductor films 48 and cathode conductor films 50.The description of substrate 14 applies equally to substrate 814.

In fuel cell system 810, ceramic seal 102 is positioned to prevent orreduce leakage of gases and liquids from substrate 814 into interconnect16 (blind interconnect 52), and extends in direction 36 between theanode 40 and anode conductor film 48 of one electrochemical cell 812 andthe anode 40 and anode conductor film 48 of an adjacent electrochemicalcell 812. In fuel cell system 810, ceramic seal 102 is positionedvertically (in direction 32) between porous substrate 814 on the bottomand blind primary conductor 52 of interconnect 16 and electrolyte 26 onthe top, thereby preventing the leakages of gases and liquids fromsubstrate 714 into the portions of blind primary conductor 52 (andelectrolyte 26) that are overlapped by ceramic seal 102. In otherembodiments, ceramic seal 102 may be disposed in other suitablelocations in addition to or in place of that illustrated in FIG. 13.Ceramic seal 102 may be formed of one or more of the materials set forthabove with respect to the embodiment of FIG. 7. A portion of blindprimary conductor 52 is embedded between ceramic seal 102 on the bottom,and electrolyte 26 on the top. The diffusion distance in the embodimentof FIG. 13 is primarily defined by the length of the overlap of blindprimary conductor 52 by both ceramic seal 102 and electrolyte 26 indirection 36.

In fuel cell system 810, chemical barrier 104 is disposed between anode40 and blind primary conductor 52, and is configured to prevent materialmigration between anode 40 and blind primary conductor 52. In one form,chemical barrier 104 also functions as auxiliary conductor 54. In otherembodiments, auxiliary conductor 54 may be formed separately fromchemical barrier 104. Chemical barrier 104 may be formed from one ormore of the materials set forth above with respect to the embodiments ofFIGS. 10-15.

Referring to FIG. 14, some aspects of a non-limiting example of anembodiment of a fuel cell system 910 disposed on a substrate 914 areschematically depicted. Fuel cell system 910 includes a chemical barrier104. Fuel cell system 910 also includes some the components set forthabove and described with respect to fuel cell system 10, e.g., includingan interconnects 16 having a blind primary conductor 52; an oxidant side18; a fuel side 20; electrolyte layers 26; anodes 40; and cathodes 42.Although only a single instance of interconnect 16, blind primaryconductor 52, anode 40 and cathode 42 are depicted, and two instances ofelectrolyte layers 26 are depicted, it will be understood that fuel cellsystem 910 may include a plurality of each such components, e.g.,arranged in series in direction 36, e.g., similar to embodimentsdescribed above. The description of substrate 14 applies equally tosubstrate 914. In fuel cell system 910, chemical barrier 104 is disposedbetween cathode 42 and interconnect 16 (blind primary conductor 52),extending in direction 32 between cathode 42 and interconnect 16, and isconfigured to prevent material migration between cathode 42 andinterconnect 16 (blind primary conductor 52). Chemical barrier 104 maybe formed from one or more of the materials set forth above with respectto the embodiments of FIGS. 10-15.

Referring to FIG. 15, some aspects of a non-limiting example of anembodiment of a fuel cell system 1010 are schematically depicted. Fuelcell system 1010 includes a plurality of electrochemical cells 612disposed on a substrate 1014, each electrochemical cell 1012 including achemical barrier 104. Fuel cell system 1010 also includes the componentsset forth above and described with respect to fuel cell system 10, e.g.,including interconnects 16 having blind primary conductors 52 and blindauxiliary conductors or vias 54 and 56; an oxidant side 18; a fuel side20; electrolyte layers 26; anodes 40; cathodes 42, anode conductor films48 and cathode conductor films 50. The description of substrate 14applies equally to substrate 1014. In fuel cell system 1010, chemicalbarrier 104 is disposed between cathode conductor film 50 andinterconnect 16 (blind primary conductor 52), extending in direction 32between cathode conductor film 50 and interconnect 16 (blind primaryconductor 52), and is configured to prevent material migration betweencathode conductor film 50 and interconnect 16 (blind primary conductor52). Chemical barrier 104 may be formed from one or more of thematerials set forth above with respect to the embodiments of FIGS.10-15. In the embodiment of FIG. 15, chemical barrier 104 also functionsas auxiliary conductor 56.

In the embodiments of FIGS. 10-15, various features, components andinterrelationships therebetween of aspects of embodiments of the presentinvention are depicted. However, the present invention is not limited tothe particular embodiments of FIGS. 10-15 and the components, featuresand interrelationships therebetween as are illustrated in FIGS. 10-15and described herein.

Referring to FIGS. 16-19 generally, the inventors have determined thatin some fuel cells, under some operating conditions, the cathodeconductive layer/conductor film, the electrolyte, and portions of theinterconnect, e.g., vias, can form parasitic cells within or betweeneach electrochemical cell, particularly where there is overlap betweenthe cathode conductive layer/conductor film and the electrolyte. In theparasitic cells, the cathode conductive layer/conductor film functionsas a cathode, and the interconnect, e.g., vias formed of precious metalcermet, function as an anode. The parasitic cells consume fuel duringfuel cell operation, thereby reducing the efficiency of the fuel cellsystem. In addition, the steam generated by the parasitic cells maycreate local high oxygen partial pressure that may result in theoxidation of Ni that may have diffused into precious metal phase of theinterconnect (e.g., via) materials, resulting in degradation of theinterconnect.

The inventors performed tests that confirmed the existence of parasiticcells. The tests confirmed that, although significant degradation didnot occur at some temperatures, e.g., 900° C., under the testing times,degradation of the interconnect occurred at higher operatingtemperatures, e.g., 925° C. after approximately 700 hours of testing.Post test analysis showed Ni migration from the anode conductivelayer/conductor film side to the cathode conductive layer/conductor filmside of the interconnect through the precious metal phase in blindprimary conductor 52, which was accelerated by the higher operatingtemperature. A high oxygen partial pressure resulting from steam formedby the parasitic cells caused Ni oxidation at the interface of extendedelectrolyte 26 and blind primary interconnect 52 near the boundarybetween the cathode conductive layer/conductor film and the electrolyte,which segregated from the precious metal of the interconnect. ContinuedNiO accumulation at the interface between the blind primary conductor 52and the electrolyte 26, and continued Ni migration would likely resultin failure of the interconnect.

In order to prevent overlap between the cathode conductivelayer/conductor film and the electrolyte, in various embodiments theinventors employed a separation feature (gap 106 of FIGS. 16 and 17; andinsulator 108 of FIGS. 18 and 19) between the cathode conductivelayer/conductor film and the electrolyte to separate, i.e., space apart,the cathode conductive layer/conductor film and the electrolyte fromcontacting each other, thus eliminating the parasitic cells. Testing offuel cell systems with a separation feature in the form of gap 106 (andalso including a chemical barrier 104 formed of Pd—Ni alloy cermet) forapproximately 2000 hours, including approximately 1000 hours ataggressive conditions (925° C. and fuel consisting of 20% H₂, 10% CO,19% CO₂, 47% steam and 4% N₂) did not result in degradation of theinterconnect. Accordingly, some embodiments of the present inventioninclude a separation feature, e.g., gap 106, between the cathodeconductive layer/conductor film and the electrolyte, which prevents theestablishment of parasitic cells.

Referring to FIG. 16, some aspects of a non-limiting example of anembodiment of a fuel cell system 1110 are schematically depicted. Fuelcell system 1110 includes a plurality of electrochemical cells 1112disposed on a substrate 1114, each electrochemical cell 1112 including aceramic seal 102, a chemical barrier 104, and a separation feature inthe form of gap 106. Fuel cell system 1110 also includes the componentsset forth above and described with respect to fuel cell system 10, e.g.,including interconnects 16 having blind primary conductors 52 and blindauxiliary conductors or vias 54 and 56; an oxidant side 18; a fuel side20; electrolyte layers 26; anodes 40; cathodes 42, anode conductor films48 and cathode conductor films 50. The description of substrate 14applies equally to substrate 1114. Gap 106 extends in direction 36between cathode conductor film 50 (e.g., formed of one or more cathodeconductive layers 30) and electrolyte layer 26.

In fuel cell system 1110, ceramic seal 102 is positioned to prevent orreduce leakage of gases and liquids from substrate 1114 intointerconnect 16 (blind primary conductor 52), and extends in direction36 between the anode conductor film 48 of one electrochemical cell 1112and the auxiliary conductor 54 of an adjacent electrochemical cell 1112.

In fuel cell system 1110, ceramic seal 102 is positioned vertically (indirection 32) between porous substrate 1114 on the bottom and blindprimary conductor 52 of interconnect 16 and electrolyte 26 on the top,thereby preventing the leakages of gases and liquids from substrate 1114into the portions of blind primary conductor 52 (and electrolyte 26)that are overlapped by ceramic seal 102. In other embodiments, ceramicseal 102 may be disposed in other suitable locations in addition to orin place of that illustrated in FIG. 12. Ceramic seal 102 may be formedof one or more of the materials set forth above with respect to theembodiment of FIG. 7. A portion of blind primary conductor 52 isembedded between ceramic seal 102 on the bottom, and extendedelectrolyte 26 on the top. The diffusion distance in the embodiment ofFIG. 16 is primarily defined by the length of the overlap of blindprimary conductor 52 by both ceramic seal 102 and electrolyte 26 indirection 36.

In fuel cell system 1110, chemical barrier 104 is disposed between anodeconductor film 48 and interconnect 16 (blind primary conductor 52),extending in direction 32 between anode conductor film 48 and both blindprimary conductor 52 and auxiliary conductor 54 of interconnect 16, andis configured to prevent material migration between anode conductor film48 and blind primary conductor 52 and auxiliary conductor 54. Chemicalbarrier 104 may be formed from one or more of the materials set forthabove with respect to the embodiments of FIGS. 10-15.

In fuel cell system 1110, gap 106 is configured to prevent formation ofa parasitic fuel cell between cathode conductor film 50, electrolytelayer 26 and blind primary conductor 52. Although gap 106 in theembodiment of FIG. 16 is employed in conjunction with a fuel cell systemhaving ceramic seal 102, chemical barrier 104 and anode conductor film48, in other embodiments, gap 106 may be employed in fuel cell systemsthat do not include components corresponding to one or more of ceramicseal 102, chemical barrier 104 and anode conductor film 48.

Referring to FIG. 17, some aspects of a non-limiting example of anembodiment of a fuel cell system 1210 are schematically depicted. Fuelcell system 1210 includes a plurality of electrochemical cells 1212disposed on a substrate 1214, each electrochemical cell 1212 including achemical barrier 104 and a separation feature in the form of gap 106.Fuel cell system 1210 also includes the components set forth above anddescribed with respect to fuel cell system 10, e.g., includinginterconnects 16 having blind primary conductors 52 and blind auxiliaryconductors or vias 54 and 56; an oxidant side 18; a fuel side 20;electrolyte layers 26; anodes 40; cathodes 42, anode conductor films 48and cathode conductor films 50. The description of substrate 14 appliesequally to substrate 1214.

In fuel cell system 1210, chemical barrier 104 is disposed between anodeconductor film 48 and interconnect 16 (blind primary conductor 52),extending in direction 32 between anode conductor film 48 andinterconnect 16, and is configured to prevent material migration betweenanode conductor film 48 and interconnect 16 (blind primary conductor52). Chemical barrier 104 may be formed from one or more of thematerials set forth above with respect to the embodiments of FIGS.10-15. In fuel cell system 1210, a portion of electrolyte layer 26 isdisposed between anode 40 and chemical barrier 104, extending indirection 36 between anode 40 and chemical barrier 104.

In fuel cell system 1210, gap 106 is configured to prevent formation ofa parasitic fuel cell between auxiliary conductor 56 (formed of the samematerial as cathode conductor film 50), electrolyte layer 26 and blindprimary conductor 52. Although gap 106 in the embodiment of FIG. 17 isemployed in conjunction with a fuel cell system having chemical barrier104 and anode conductor film 48, in other embodiments, gap 106 may beemployed in fuel cell systems that do not include componentscorresponding to one or more of chemical barrier 104 and anode conductorfilm 48.

Referring to FIG. 18, some aspects of a non-limiting example of anembodiment of a fuel cell system 1310 are schematically depicted. Fuelcell system 1310 includes a plurality of electrochemical cells 1312disposed on a substrate 1314, each electrochemical cell 1312 including aceramic seal 102, a chemical barrier 104, and a separation feature inthe form of an insulator 108. Fuel cell system 1310 also includes thecomponents set forth above and described with respect to fuel cellsystem 10, e.g., including interconnects 16 having blind primaryconductors 52 and blind auxiliary conductors or vias 54 and 56; anoxidant side 18; a fuel side 20; electrolyte layers 26; anodes 40;cathodes 42, anode conductor films 48 and cathode conductor films 50.The description of substrate 14 applies equally to substrate 1314.Insulator 108 extends in direction 36 between cathode conductor film 50(e.g., formed of one or more cathode conductive layers 30) andelectrolyte layer 26.

In fuel cell system 1310, ceramic seal 102 is positioned to prevent orreduce leakage of gases and liquids from substrate 1314 intointerconnect 16 (blind primary conductor 52), and extends in direction36 between the anode conductor film 48 of one electrochemical cell 1312and the auxiliary conductor 54 of an adjacent electrochemical cell 1312.

In fuel cell system 1310, ceramic seal 102 is positioned vertically (indirection 32) between porous substrate 1314 on the bottom and blindprimary conductor 52 of interconnect 16 and electrolyte 26 on the top,thereby preventing the leakages of gases and liquids from substrate 1314into the portions of blind primary conductor 52 (and electrolyte 26)that are overlapped by ceramic seal 102. In other embodiments, ceramicseal 102 may be disposed in other suitable locations in addition to orin place of that illustrated in FIG. 12. Ceramic seal 102 may be formedof one or more of the materials set forth above with respect to theembodiment of FIG. 7. A portion of blind primary conductor 52 isembedded between ceramic seal 102 on the bottom, and extendedelectrolyte 26 on the top. The diffusion distance in the embodiment ofFIG. 18 is primarily defined by the length of the overlap of blindprimary conductor 52 by both ceramic seal 102 and electrolyte 26 indirection 36.

In fuel cell system 1310, chemical barrier 104 is disposed between anodeconductor film 48 and interconnect 16 (blind primary conductor 52),extending in direction 32 between anode conductor film 48 and both blindprimary conductor 52 and auxiliary conductor 54 of interconnect 16, andis configured to prevent material migration between anode conductor film48 and blind primary conductor 52 and auxiliary conductor 54. Chemicalbarrier 104 may be formed from one or more of the materials set forthabove with respect to the embodiments of FIGS. 10-15.

In fuel cell system 1310, insulator 108 is configured to preventformation of a parasitic fuel cell between cathode conductor film 50,electrolyte layer 26 and blind primary conductor 52. In one form,insulator 108 is formed from an insulating non-conductive materials,such as aluminum oxide (Al₂O₃), pyrochlore, such as In otherembodiments, La₂Zr₂O₇, Pr₂Zr₂O₇, and SrZrO₃. other materials may beemployed to form insulator 108, e.g., one or more other types ofnon-conducting ceramics in addition to or in place of aluminum oxide.Although insulator 108 in the embodiment of FIG. 16 is employed inconjunction with a fuel cell system having ceramic seal 102, chemicalbarrier 104 and anode conductor film 48, in other embodiments, insulator108 may be employed in fuel cell systems that do not include componentscorresponding to one or more of ceramic seal 102, chemical barrier 104and anode conductor film 48.

Referring to FIG. 19, some aspects of a non-limiting example of anembodiment of a fuel cell system 1410 are schematically depicted. Fuelcell system 1410 includes a plurality of electrochemical cells 1412disposed on a substrate 1414, each electrochemical cell 1412 including achemical barrier 104 and a separation feature in the form of insulator108. Fuel cell system 1410 also includes the components set forth aboveand described with respect to fuel cell system 10, e.g., includinginterconnects 16 having blind primary conductors 52 and blind auxiliaryconductors or vias 54 and 56; an oxidant side 18; a fuel side 20;electrolyte layers 26; anodes 40; cathodes 42, anode conductor films 48and cathode conductor films 50. The description of substrate 14 appliesequally to substrate 1414.

In fuel cell system 1410, chemical barrier 104 is disposed between anodeconductor film 48 and interconnect 16 (blind primary conductor 52),extending in direction 32 between anode conductor film 48 andinterconnect 16, and is configured to prevent material migration betweenanode conductor film 48 and interconnect 16 (blind primary conductor52). Chemical barrier 104 may be formed from one or more of thematerials set forth above with respect to the embodiments of FIGS.10-15. In fuel cell system 1410, a portion of electrolyte layer 26 isdisposed between anode 40 and chemical barrier 104, extending indirection 36 between anode 40 and chemical barrier 104.

In fuel cell system 1410, insulator 108 is configured to preventformation of a parasitic fuel cell between auxiliary conductor 56(formed of the same material as cathode conductor film 50), electrolytelayer 26 and blind primary conductor 52. Insulator 108 may be formed ofthe materials set forth above in the embodiment of FIG. 18. Althoughinsulator 108 in the embodiment of FIG. 19 is employed in conjunctionwith a fuel cell system having chemical barrier 104 and anode conductorfilm 48, in other embodiments, insulator 108 may be employed in fuelcell systems that do not include components corresponding to one or moreof chemical barrier 104 and anode conductor film 48.

In the embodiments of FIGS. 16-19, various features, components andinterrelationships therebetween of aspects of embodiments of the presentinvention are depicted. However, the present invention is not limited tothe particular embodiments of FIGS. 16-19 and the components, featuresand interrelationships therebetween as are illustrated in FIGS. 16-19and described herein.

As mentioned above with respect to FIGS. 16-19, under certainconditions, parasitic cells may be undesirably formed. The embodimentsdiscussed above with respect to FIGS. 16-19 provide certain approachesto resolving the parasitic cell problem. The inventors have also createdother approaches to solving the parasitic cell problem, based onmaterial selection, e.g., the material from which the interconnectand/or vias (e.g., interconnect 16, including blind primary conductor52, auxiliary conductor 54 and/or auxiliary conductor 56, and/or otherinterconnect and/or via configurations not mentioned herein) are formed.In one form, for an alternate cermet material, precious metal —La₂Zr₂O₇pyrochlore cermet may be employed for primary interconnect material forsegmented-in-series fuel cell, or via material for multi-layer ceramicinterconnect. In the such a cermet material, La₂Zr₂O₇ pyrochlore couldfully replace doped zirconia, or partially replace doped zirconia tokeep ionic phase below its percolation to eliminate or reduce ionicconduction.

In one form, the composition of the interconnect and/or via(s), e.g.,one or more of the previously mentioned compositions for theinterconnect and/or via(s), is altered to include non-ionic conductingceramic phases in the composition of the interconnect and/or via(s).

For example, in one form, the interconnect and/or via may be formed, allor in part, of a cermet, such as those previously described with respectto interconnect 16, including blind primary conductor 52, auxiliaryconductor 54 and/or auxiliary conductor 56, but also or alternativelyincluding one or more non-ionic conductive ceramic phases. Examplesinclude, without limitation, SrZrO₃, La₂Zr₂O₇ pyrochlore, Pr₂Zr₂O₇pyrochlore, BaZrO₃, MgAl₂O₄ spinel, NiAl₂O₄ spinel, MgCr₂O₄ spinel,NiCr₂O₄ spinel, Y₃Al₅O₁₂ and other garnets with various A- and B-sitesubstitution, and alumina. Other non-ionic conductive ceramic phases arealso contemplated herein in addition to or in place of the examples setforth herein. Considerations for materials may include the coefficientof thermal expansion of the ceramic phase(s), e.g., relative to thecoefficient thermal expansion of the porous substrate. In someembodiments, preferred materials for chemical compatibility withadjacent fuel cell layers may include precious metal-pyrochlore cermets,wherein the general class of pyrochlores is (M_(RE))₂Zr₂O₇, whereinM_(RE) is a rare earth cation, for example and without limitation La,Pr, Nd, Gd, Sm, Ho, Er, and/or Yb.

In other embodiments, nonionic phases such as SrZrO₃, MgAl₂O₄ spinel,NiAl₂O₄ spinel, alumina and pyrochlore compositions partially orcompletely replace the ionic conducting YSZ, e.g., of previouslydescribed interconnects and/or vias. Preferably, pyrochlore powdersand/or one or more of the other nonionic phases replace YSZ sufficientlyto render the balance of the YSZ to be below a percolation threshold toeliminate ionic conductivity across the interconnect/via. The YSZ volumefraction of the via is purposely reduced to less than 30v % to minimizeany ionic conductivity within the via material.

In one form, the composition of the interconnect and/or via(s), e.g.,one or more of the previously mentioned compositions for theinterconnect and/or via(s), is altered to include a reactant phase toform non-ionic conducting ceramic phases during firing of the fuel cell,e.g., by the inclusion of rare earth oxides in the compound used to formthe interconnect/via(s).

For example, in some embodiments, all or portions interconnect 16 orother interconnects or vias may include a reactant phase in the form ofrare earth oxide, e.g., within the screen printing ink, at less than thestoichiometric ratio to form pyrochlore being one mole of the oxides ofLa, Pr, Nd, Gd, Sm, Ho, Er, Yb to two moles of the zirconia content ofthe via. In the overall cermet composition (e.g., cermet compositionsfor all or part of interconnect 16 set forth herein) which reacts withthe YSZ during firing of the fuel cell to form pyrochlore within theinterconnect/via and adjacent to the electrolyte, e.g., electrolyte 26.In one form, the minimum rare earth oxide required is about 13 mole %ceramic composition in order to reduce YSZ phase below 30v %percolation. In other embodiments, other rare earth oxide amounts may beemployed. The zirconia phase may still be able to exist at greater thanthe percolation threshold, since the insulating pyrochlore phase couldform along grain boundaries. However, in some embodiments, it would bepreferable to add sufficient rare earth oxides to take the YSZ phasecontent to below the percolation threshold on a bulk composition basis.Similar to the pyrochlores, SrZrO₃ nonionic phases could be createdin-situ through addition of SrO powder as a reactant phase, e.g., to theinterconnect inks, at less than the stoichimetric ratio of 1 mole SrO to1 mole ZrO₂.

In still other embodiments, all or portions interconnect 16 or otherinterconnects or vias may include a content of rare earth oxide, e.g.,within the screen printing ink, at greater than the stoichiometric ratioof pyrochlore being one mole of the oxides, e.g., of La, Pr, Nd, Gd, Sm,Ho, Er, and/or Yb, to two moles of the zirconia content of the via inthe overall cermet composition (e.g., cermet compositions for all orpart of interconnect 16 set forth herein) which reacts with the YSZduring firing of the fuel cell to form pyrochlore within theinterconnect/via, and the unreacted rare earth oxide will further reactwith the extended electrolyte in the vicinity of the interconnect duringelectrolyte firing to form a pyrochlore film on the electrolyte surface,e.g., on the surface of electrolyte 26, which will sufficiently disruptthe pathways for oxygen ionic conductivity. In form, the rare earthoxide amount is from 33 mole % to 50 mole % based on the total ceramicphase. In other embodiments, other rare earth oxide amounts may beemployed. The excess rare earth oxide may ensure the absence of ionicconductivity. However, too much excess rare earth remaining within theinterconnect/via could cause the via to be susceptible to moistureinduced damage on phase change to the rare earth hydroxides. Hence, itis desirable in some embodiments to limit the amount of rare earthoxides to less than 10% over the stoichiometric ratio. Similar to thepyrochlores, SrZrO₃ nonionic phases could be created in-situ within thevia and adjacent extended electrolyte through addition of SrO powder tothe interconnect inks in excess of the stoichimetric ratio of 1 mole SrOto 1 mole ZrO₂. In one form, a lower limit is approximately 15-20 mole %SrO based on the ceramic phase, in order to form SrZrO3 to reduce YSZbelow the percolation threshold. In other embodiments, other lowerlimits may apply. In one form, an upper limit is about 50-60 mole % SrObased on the ceramic phase (SrO+ZrO2). In other embodiments, other upperlimits may apply.

In yet still other embodiments, all or portions interconnect 16 or otherinterconnects or vias may include a content of rare earth oxide at thestoichiometric ratio with YSZ to lead to full reactivity to(M_(RE))₂Zr₂O₇.

Firing temperatures for using a reactant phase to form the non-ionicconducting ceramic phases during firing of the fuel cell may vary withthe needs of the particular application. Considerations include, forexample and without limitation, the sinterability of differentmaterials, powder particle size, specific surface area. Other materialand/or processing parameters may also affect the selected firingtemperature. For example, If the temperature is too low, the electrolytemay have higher porosity and cause leakage. If the temperature is toohigh, it may cause other issues, such as too high an anode density,which may reduce electrochemical activity, or may cause substratedimensional changes, etc. Hence, the actual firing temperature forpurposes of using one or more reactant phases to form one or morenon-ionic conducting ceramic phases may vary as between applications. Inone form, the firing temperature may be 1385° C. In some embodiments,the firing temperature may be in the range of 1370° C. to 1395° C. Inother embodiments, the firing temperature may be in the range of 1350°C. to 1450° C. In still other embodiments, the firing temperature may beoutside the range of 1350° C. to 1450° C. Processing steps to form theone or more non-ionic conducting ceramic phases may include preparing acomposition including the rare earth oxide, YSZ and a precious metal,forming the interconnect/via(s), firing the composition at the desiredtemperature, e.g., at a temperature or within a temperature range setforth above, and holding the composition at the firing temperature for adesired period, e.g., in the range of 1-5 hours. In embodiments whereinall or portions of the fuel cell are formed by screen printing, themethod may include preparing a screen printable ink that incorporatesthe rare earth oxide, YSZ and the precious metal; printing theinterconnect/via(s); drying the ink; firing the printedinterconnect/via(s) at the desired temperature, e.g., at a temperatureor within a temperature range set forth above; and holding thecomposition at the firing temperature for a desired period, e.g., in therange of 1-5 hours.

In additional embodiments, other non-ionic conducting phases or reactantphases may be employed to minimize the ionic conductivity of theinterconnect.

The following Tables 1-8 provide compositional information for someaspects of non-limiting experimental fuel cell and fuel cell componentexamples produced in accordance with some aspects of some embodiments ofthe present invention. It will be understood the present invention is inno way limited to the examples provided below. The columns entitled“General Composition” illustrate some potential compositional ranges,including some preferred ranges, for some materials described herein,whereas, the columns entitled “Specific Composition” illustrates thematerials used in the test articles/materials.

TABLE 1 (w/o ceramic seal) General Composition Specific CompositionAnode NiO—YSZ (NiO = 55-75 wt %) Anode conductive layer Pd—Ni—YSZCathode La_((1−x))Sr_(x)MnO_((3−d))(x = 0.1-0.3) —3YSZ Cathodeconductive layer Pd—La_((1−x))Sr_(x)MnO_((3−d)) (x = 0.1-0.3)Electrolyte 3YSZ 3YSZ Blind primary conductor xPd(100 − x)Pt—YSZ (x =35-65 wt ratio, 31.1%Pd, 31.1%Pt, 24.4% 3YSZ alloy is 35-80 v %)Auxiliary conductor on anode side xPd(100 − x)Pt—YSZ (x = 35-65 wtratio, 31.1%Pd, 31.1%Pt, 24.4% 3YSZ alloy is 35-80 v %) Auxiliaryconductor on cathode side Pd—La_((1−x))Sr_(x)MnO_((3−d)) (x = 0.1-0.3)Substrate MgO—MgAl₂O₄ 69.4%MgO, 30.6%MgAl₂O₄ Substrate surfacemodification layer 3-8 mol %Y₂O₃—ZrO₂ 8YSZ Ceramic seal N/A N/A CellASR, ohm-cm{circumflex over ( )}2  0.375 Interconnect ASR,ohm-cm{circumflex over ( )}2  0.027 Test duration, hrs 860 Examples:TCT23 (STC13-3): blind primary interconnect is long strip design FIG. 4

TABLE 2 (w/o ceramic seal) General Composition Specific CompositionAnode NiO—YSZ (NiO = 55-75 wt %) Anode conductive layer Pd—Ni—YSZCathode La_((1−x))Sr_(x)MnO_((3−d))(x = 0.1-0.3) —3YSZ Cathodeconductive layer Pd—La_((1−x))Sr_(x)MnO_((3−d)) (x = 0.1-0.3)Electrolyte 3YSZ 3YSZ Blind primary conductor xPd(100 − x)Pt—YSZ (x =35-65 wt ratio, 31.1%Pd, 31.1%Pt, 24.4% 3YSZ alloy is 35-80 v %)Auxiliary conductor on anode side xPd(100 − x)Pt—YSZ (x = 35-65 wtratio, 31.1%Pd, 31.1%Pt, 24.4% 3YSZ alloy is 35-80 v %)Pd—La_((1−x))Sr_(x)MnO_((3−d)) (x = 0.1-0.3) Substrate MgO−MgAl₂O₄69.4%MgO, 30.6%MgAl₂O₄ Substrate surface modification layer 3-8 mol%Y₂O₃—ZrO₂ 8YSZ Ceramic seal N/A cell ASR, ohm-cm{circumflex over ( )}2  0.30 Interconnect ASR, ohm-cm{circumflex over ( )}2   0.02 Testduration, hrs 3500 Examples: PCT11(PC08-2/3): blind primary interconnectis via design FIG. 6

TABLE 3 (with ceramic seal) General Composition Specific CompositionAnode NiO—YSZ (NiO = 55-75 wt %) Anode conductive layer Pd—Ni—YSZCathode La_((1−x))Sr_(x)MnO_((3−δ))(x = 0.1-0.3) —3YSZ Cathodeconductive layer Pd—La_((1−x))Sr_(x)MnO_((3−δ)) (x = 0.1-0.3)Electrolyte 3YSZ 3YSZ Blind primary conductor Pd—Ni—YSZ 76.5%Pd, 8.5%Ni,15%3YSZ Auxiliary conductor on anode side Pd—Ni—YSZ 76.5%Pd, 8.5%Ni,15%3YSZ Auxiliary conductor on cathode sidePd—La_((1−x))Sr_(x)MnO_((3−δ)) (x = 0.1-0.3) Substrate MgO—MgAl₂O₄69.4%MgO, 30.6%MgAl₂O₄ Substrate surface modification layer 3-8 mol%Y₂O₃—ZrO₂ 8YSZ Ceramic seal 3-5 mol %Y₂O₃—ZrO₂, or 3YSZ 4-6 mol%Sc₂O₃—ZrO₂ cell & interconnect ASR, ohm-cm{circumflex over ( )}2   0.50Test duration, hrs 1200 Examples: TCT2: blind primary interconnect islong strip design FIG. 8

TABLE 4 (Pd—NTZ as chemical barrier) General Composition SpecificComposition Anode NiO—YSZ (NiO = 55-75 wt %) Anode conductive layerPd—NiO—(Mg_(0.42),Ni_(0.58))Al₂O₄ Cathode La_((1−x))Sr_(x)MnO_((3−δ))(x= 0.1-0.3) —3YSZ Cathode conductive layer La_((1−x))Sr_(x)MnO_((3−d)) (x= 0.1-0.3) Electrolyte 3-8 mol %Y₂O₃—ZrO₂, or 3YSZ 4-11 mol %Sc₂O₃—ZrO₂Blind primary conductor xPd(100 − x)Pt—YSZ (x = 35-65 wt ratio, 31.1%Pd,31.1%Pt, 24.4% 3YSZ alloy is 35-80 v %) Chemical barrier on anode sidexPd—(100 − x) NTZ* (x = 10-40) 15%Pd, 19%NiO, 66%NTZ Auxiliary conductoron La(1 − x)SrxMnO(3 − d) (x = 0.1-0.3) cathode side SubstrateMgO—MgAl₂O₄ 69.4%MgO, 30.6%MgAl₂O₄ Substrate surface 3-8 mol %Y₂O₃—ZrO₂8YSZ modification layer Ceramic seal N/A N/A Cell ASR, ohm-cm{circumflexover ( )}2   0.35 Interconnect ASR, ohm-cm{circumflex over ( )}20.02-0.05 Test duration, hrs 1400 *NTZ: 73.6 wt %NiO, 20.0%TiO₂, 6.4%YSZ Examples: PCT14B (PC11-4), blind vias, FIG. 11

TABLE 5 wt % (GDC10 as chemical barrier) General Composition SpecificComposition Anode NiO—YSZ (NiO = 55-75 wt %) Anode conductive layerPd—NiO—(Mg_(0.42),Ni_(0.58))Al₂O₄ Cathode La_((1−x))Sr_(x)MnO_((3−δ))(x= 0.1-0.3) —3YSZ Cathode conductive layer La_((1−x))Sr_(x)MnO_((3−d)) (x= 0.1-0.3) Electrolyte 3-8 mol %Y₂O₃—ZrO₂, or 3YSZ 4-11 mol %Sc₂O₃—ZrO₂Blind primary conductor xPd—(100 − x)YSZ (x = 70-90 weight ratio) 85%Pd,15%3YSZ Chemical barrier on anode side Doped Ceria (Gd_(0.1),Ce_(0.9))O₂Auxiliary conductor on La_((1−x))Sr_(x)MnO_((3−d)) (x = 0.1-0.3) cathodeside Substrate MgO—MgAl₂O₄ 69.4%MgO, 30.6%MgAl₂O₄ Substrate surface 3-8mol %Y₂O₃—ZrO₂ 8YSZ modification layer Ceramic seal 3-5 mol %Y₂O₃—ZrO₂,or 3YSZ 4-6 mol %Sc₂O₃—ZrO₂ Cell ASR, ohm-cm{circumflex over ( )}2  0.24 Interconnect ASR, ohm-cm{circumflex over ( )}2 0.04-0.05 Testduration, hrs 1340 Examples: PCT55A (PC28-2) for FIG. 12

TABLE 6 wt % General Composition Specific Composition Anode NiO—YSZ (NiO= 55-75 wt %) Anode conductive layer Pd—NiO—(Mg_(0.42),Ni_(0.58))Al₂O₄Cathode La_((1−x))Sr_(x)MnO_((3−δ))(x = 0.1-0.3) —3YSZ Cathodeconductive layer La_((1−x))Sr_(x)MnO_((3−d)) (x = 0.1-0.3), orLaNi_(0.6)Fe_(0.4)O₃ Electrolyte 4-11 mol % Sc₂O₃—ZrO₂ 6ScSZ Blindprimary conductor xPd(100 − x)Pt—YSZ (x = 35-65 wt ratio, 31.1%Pd,31.1%Pt, 24.4% 3YSZ alloy is 35-80 v %) Chemical barrier on anode sideDoped Ceria (Gd_(0.1),Ce_(0.9))O₂ Auxiliary conductor onLa_((1−x))Sr_(x)MnO_((3−d)) (x = 0.1-0.3), or cathode sideLaNi_(0.6)Fe_(0.4)O₃ Substrate MgO—MgAl₂O₄ 69.4%MgO, 30.6%MgAl₂O₄Substrate surface 3-8 mol %Y₂O₃—ZrO₂ 8YSZ modification layer Ceramicseal 3-5 mol %Y₂O₃—ZrO₂, or 3YSZ 4-6 mol %Sc₂O₃—ZrO₂ Cell ASR,ohm-cm{circumflex over ( )}2   0.24 Interconnect ASR, ohm-cm{circumflexover ( )}2 0.05-0.06 Test duration, hrs 8000 Examples: PCT63A&B For FIG.16

TABLE 7 General Composition Specific Composition Anode Anode conductivelayer Cathode Cathode conductive layer Electrolyte Blind primaryconductor Pt—YSZ—SrZrO3 78.8%Pt—11.1%3YSZ—10.1%SrZrO3 Auxiliaryconductor on anode side Auxiliary conductor on cathode side SubstrateSubstrate surface modification layer Ceramic seal Cell ASR,ohm-cm{circumflex over ( )}2 Interconnect ASR, ohm-cm{circumflex over( )}2 Examples: not tested in an actual SOFC test article, pelletformulation

TABLE 8 General Composition Specific Composition Anode NiO—YSZ (NiO =55-75 wt %) Anode conductive layer Pd—NiO—(Mg_(0.42),Ni_(0.58))Al₂O₄Cathode La_((1−x))Sr_(x)MnO_((3−δ))(x = 0.1-0.3) —3YSZ Cathodeconductive layer La_((1−x))Sr_(x)MnO_((3−d)) (x = 0.1-0.3) Electrolyte3-8 mol %Y₂O₃—ZrO₂ 3YSZ Blind primary conductor Pt—Pd—YSZ—La₂O₃36%Pt—36%Pd—25.2%3YSZ—2.8%La₂O₃ Auxiliary conductor on anode sidePt—Pd—YSZ—La₂O₃ 36%Pt—36%Pd—25.2%3YSZ—2.8%La₂O₃ Auxiliary conductor onLa_((1−x))Sr_(x)MnO_((3−d)) (x = 0.1-0.3) cathode side SubstrateMgO—MgAl₂O₄ 69.4%MgO, 30.6%MgAl₂O₄ Substrate surface 3-8 mol %Y₂O₃—ZrO₂8YSZ modification layer Ceramic seal 3-5 mol %Y₂O₃—ZrO₂, or 3YSZ 4-6 mol%Sc₂O₃—ZrO₂ Cell ASR, ohm-cm{circumflex over ( )}2  0.3-0.34Interconnect ASR, ohm-cm{circumflex over ( )}2 0.04-0.07 Examples: PCT57

Embodiments of the present invention include a fuel cell system,comprising: a plurality of electrochemical cells formed of an anodelayer, a cathode layer spaced apart from the anode layer, and anelectrolyte layer disposed between the anode layer and the cathodelayer; and an interconnect structured to conduct free electrons betweenelectrochemical cells, each interconnect having a primary conductorembedded within the electrolyte layer, and a pair of auxiliaryconductors electrically connecting the primary conductor with an anodelayer of one electrochemical cell and a cathode layer of anotherelectrochemical cell, respectively.

In a refinement, the primary conductor has a diffusion distance throughthe electrolyte layer that is greater than a thickness of theelectrolyte layer.

In another refinement, the diffusion distance is at least ten times thethickness of the electrolyte layer.

In yet another refinement, the primary conductor defines a diffusionflow orifice structured to limit diffusion of a fluid through theprimary conductor.

In still another refinement, the primary conductor includes a first end,a second end and a body extending between the first end and the secondend, wherein the first end and the second end are blind ends.

In yet still another refinement, the plurality of electrochemical cellsare arranged to form a segmented-in-series solid oxide fuel cell.

In a further refinement, the plurality of electrochemical cells furtherincludes: an anode conductive layer adjoining the anode layer; and acathode conductive layer adjoining the cathode layer, wherein theinterconnect is electrically coupled between the anode conductive layerand the cathode conductive layer.

In a yet further refinement, the fuel cell system further comprises aporous substrate adjoining one of the anode conductive layer and thecathode conductive layer.

In a still further refinement, the fuel cell system further comprises aporous substrate adjoining one of the anode layer and the cathode layer.

In a yet still further refinement, the anode layer is subdivided into aplurality of anodes, each adjacent pair of anodes being separated by ananode gap extending in a predetermined direction; wherein the cathodelayer is subdivided into a plurality of cathodes, each adjacent pair ofcathodes being separated by a cathode gap extending in the predetermineddirection; and wherein the primary conductor defines a conduction pathencased within the electrolyte layer and oriented along thepredetermined direction.

In another further refinement, the electrolyte layer is formed of amaterial essentially impervious to diffusion therethrough of a fluidemployed by the fuel cell system.

In yet another further refinement, the fuel cell system furthercomprises an anode conductive layer adjoining the anode layer; and acathode conductive layer adjoining the cathode layer, wherein at leastone of the auxiliary conductors is structured to form a chemical barrieragainst material migration between the primary conductor and one or bothof the anode conductive layer and the cathode conductive layer.

Embodiments of the present invention include a fuel cell system,comprising: an anode layer having a plurality of anode gaps andindividual anodes; a cathode layer having a plurality of cathode gapsand individual cathodes; a solid oxide electrolyte layer disposedbetween the anode layer and the cathode layer, wherein the individualanodes, the individual cathodes and the electrolyte layer form arespective plurality of electrochemical cells; and an interconnectpositioned between each electrochemical cell in each pair of adjacentelectrochemical cells, the interconnect being structured to conductelectrical current between electrochemical cells, and the interconnectincluding a conductive film embedded within the electrolyte layer.

In a refinement, the electrolyte layer includes two electrolytesub-layers, wherein the conductive film is sandwiched between the twoelectrolyte sub-layers.

In another refinement, the conductive film is structured as a continuousstrip.

In yet another refinement, the conductive film is structured as aplurality of vias.

In a still further refinement, the anode layer is oriented along firstplane, the cathode layer is oriented along a second plane substantiallyparallel to the first plane, and the electrolyte layer is oriented alonga third plane substantially parallel to the first plane, wherein theconductive film extends in a direction substantially parallel to thefirst plane.

Embodiments of the present invention include a fuel cell system,comprising: an electrolyte; a first electrochemical cell having a firstanode, and a first cathode spaced apart in a first direction from thefirst anode by the electrolyte, the electrolyte being structured to passoxygen ions in the first direction from the first cathode to the firstanode; a second electrochemical cell having a second anode, a secondcathode spaced apart in the first direction from the second anode by theelectrolyte, the electrolyte being structured to pass oxygen ions in thefirst direction from the second cathode to the second anode; and aninterconnect structured to conduct a flow of electrons from the firstanode to the second cathode, the interconnect including a blind primaryconductor disposed in the electrolyte and configured to conduct the flowof electrons in a second direction different from the first direction.

In a refinement, the second direction is substantially perpendicular tothe first direction.

In another refinement, the second anode is spaced apart from the firstanode in a third direction substantially perpendicular to the firstdirection, wherein second direction is also substantially perpendicularto the third direction.

In yet another refinement, the interconnect further includes: a firstblind auxiliary conductor structured to conduct electrical power betweenthe first anode and the blind primary conductor; and a second blindauxiliary conductor structured to conduct electrical power between theblind primary conductor and the second cathode.

In still another refinement, the fuel cell system further comprises ananode conductive layer adjoining the first anode; and a cathodeconductive layer adjoining the second cathode, wherein at least one ofthe first blind auxiliary conductor and the second blind auxiliaryconductor is formed of a same material as a corresponding one of theanode conductive layer and the cathode conductive layer.

In yet still another refinement, the blind primary conductor is formedof at least one of a precious metal and a precious metal alloy selectedfrom the group consisting of Ag, Au, Pd, Pt, Ag—Pd, Ag—Au, Ag—Pt, Au—Pd,Au—Pt, Pt—Pd, Ag—Au—Pd, Ag—Au—Pt, and Ag—Au—Pd—Pt.

In a further refinement, the blind primary conductor is formed of atleast one of a precious metal cermet and a precious metal alloy cermet,wherein the precious metal cermet has a ceramic phase being at least oneof yttria stabilized zirconia (YSZ), scandia stabilized zirconia (ScSZ),Al₂O₃, LNF(LaNi_(x)Fe_(1-x)O₃), LSM(La_(1-x)Sr_(x)MnO₃), doped ceria,doped strontium titanate, doped yttrium chromites, and doped lanthanumchromite.

In a yet further refinement, the doped lanthanum chromite is LSCM(La_(1-x)Sr_(x)Cr_(1-y)Mn_(y)O₃).

In a still further refinement, the LSCM isLa_(0.75)Sr_(0.25)Cr_(0.5)Mn_(0.5)O₃.

In a yet still further refinement, the blind primary conductor is aconductive ceramic.

In another further refinement, the conductive-ceramic is at least one ofLNF (LaNi_(x)Fe_(1-x)O₃), LSM (La_(1-x)Sr_(x)MnO₃), doped strontiumtitanate, doped yttrium chromites, and doped lanthanum chromite.

In yet another further refinement, the doped lanthanum chromite includesLSCM (La_(1-x)Sr_(x)Cr_(1-y)Mn_(y)O₃).

In still another further refinement, the LSCM isLa_(0.75)Sr_(0.25)Cr_(0.5)Mn_(0.5)O₃.

In yet still another further refinement, the LSM isLa_(0.75)Sr_(0.25)MnO₃.

In an additional further refinement, the blind primary conductor isformed of at least one of a Ni metal cermet and a Ni alloy cermet.

In another additional further refinement, the at least one of the Nimetal cermet and the Ni alloy cermet has a ceramic phase being at leastone of YSZ, alumina, ScSZ, doped ceria and TiO₂.

Embodiments of the present invention include a fuel cell system,comprising: a substrate; a ceramic seal disposed on the substrate; anelectrode conductive layer disposed on the substrate; a first electrodeof a first electrochemical cell, wherein the first electrode is disposedon the electrode conductive layer; a second electrode of a secondelectrochemical cell; an electrolyte having a portion spaced apart fromthe ceramic seal by a gap; and an interconnect having a conductordisposed within the gap between the ceramic seal and the portion of theelectrolyte, wherein the interconnect is operative to conduct freeelectrons between the first electrode and the second electrode.

In a refinement, the electrode conductive layer abuts the ceramic seal.

In another refinement, the interconnect defines a diffusion flow orificestructured to limit diffusion of a reactant through the interconnect.

In yet another refinement, the conductor is formed of at least one of aprecious metal and a precious metal alloy selected from the groupconsisting of Ag, Au, Pd, Pt, Ag—Pd, Ag—Au, Ag—Pt, Au—Pd, Au—Pt, Pt—Pd,Ag—Au—Pd, Ag—Au—Pt, and Ag—Au—Pd—Pt.

In still another refinement, the conductor is formed of at least one ofa precious metal cermet and a precious metal alloy cermet, wherein theat least one of the precious metal cermet and the precious metal alloycermet has a ceramic phase being at least one of Al₂O₃, yttriastabilized zirconia, scandia stabilized zirconia, doped ceria,LNF(LaNi_(x)Fe_(1-x)O₃), LSM(La_(1-x)Sr_(x)MnO₃), doped strontiumtitanates, doped yttrium chromites, and doped lanthanum chromite.

In yet still another refinement, the doped lanthanum chromite is LSCM(La_(1-x)Sr_(x)Cr_(1-y)Mn_(y)O₃).

In a further refinement, the conductor is a conductive-ceramic.

In a yet further refinement, the conductive-ceramic is at least one ofLNF (LaNi_(x)Fe_(1-x)O₃), LSM (La_(1-x)Sr_(x)MnO₃), doped strontiumtitanates, doped yttrium chromites, and doped lanthanum chromite.

In a still further refinement, the doped lanthanum chromite includesLSCM (La_(1-x)Sr_(x)Cr_(1-y)Mn_(y)O₃).

In a yet still further refinement, the conductor is formed of at leastone of a Ni metal cermet and a Ni alloy cermet.

In another further refinement, the at least one of the Ni metal cermetand the Ni alloy cermet has a ceramic phase being at least one of yttriastabilized zirconia, alumina, Scandia stabilized zirconia, doped ceriaand TiO₂, doped strontium titanates, doped yttrium chromites, and dopedlanthanum chromites.

In yet another further refinement, the conductor is a blind conductor.

In still another further refinement, the fuel cell system furthercomprises an anode conductive film adjacent the anode and operative toconduct free electrons between the anode and the conductor.

In yet still another further refinement, the conductor is made from asame material as the anode conductive film.

In an additional further refinement, the conductor is an extension ofthe anode conductive film.

In another additional further refinement, the fuel cell system furthercomprises a substrate, wherein the ceramic seal is adjacent to thesubstrate.

In yet another additional further refinement, the ceramic seal is formedon the substrate.

In still another additional further refinement, a material of theceramic seal is yittria stabilized zirconia.

In yet still another additional further refinement, the yittriastabilized zirconia is 3YSZ.

In another refinement, a material of the ceramic seal is scandia dopedzirconia.

In yet another refinement, the scandia doped zirconia is 4ScSZ.

While the invention has been described in connection with what ispresently considered to be the most practical and preferred embodiment,it is to be understood that the invention is not to be limited to thedisclosed embodiment(s), but on the contrary, is intended to covervarious modifications and equivalent arrangements included within thespirit and scope of the appended claims, which scope is to be accordedthe broadest interpretation so as to encompass all such modificationsand equivalent structures as permitted under the law. Furthermore itshould be understood that while the use of the word preferable,preferably, or preferred in the description above indicates that featureso described may be more desirable, it nonetheless may not be necessaryand any embodiment lacking the same may be contemplated as within thescope of the invention, that scope being defined by the claims thatfollow. In reading the claims it is intended that when words such as“a,” “an,” “at least one” and “at least a portion” are used, there is nointention to limit the claim to only one item unless specifically statedto the contrary in the claim. Further, when the language “at least aportion” and/or “a portion” is used the item may include a portionand/or the entire item unless specifically stated to the contrary.

1. A fuel cell system, comprising: a plurality of electrochemical cellsformed of an anode layer, a cathode layer spaced apart from said anodelayer, and an electrolyte layer disposed between said anode layer andsaid cathode layer; and an interconnect structured to conduct freeelectrons between electrochemical cells, each interconnect having aprimary conductor embedded within said electrolyte layer, and a pair ofauxiliary conductors electrically connecting said primary conductor withan anode layer of one electrochemical cell and a cathode layer ofanother electrochemical cell, respectively.
 2. The fuel cell system ofclaim 1, wherein said primary conductor has a diffusion distance throughsaid electrolyte layer that is greater than a thickness of saidelectrolyte layer.
 3. The fuel cell system of claim 2, wherein thediffusion distance is at least ten times the thickness of saidelectrolyte layer.
 4. The fuel cell system of claim 1, wherein saidprimary conductor defines a diffusion flow orifice structured to limitdiffusion of a fluid through said primary conductor.
 5. The fuel cellsystem of claim 1, wherein said primary conductor includes a first end,a second end and a body extending between the first end and the secondend, wherein the first end and the second end are blind ends.
 6. Thefuel cell system of claim 1, wherein said plurality of electrochemicalcells are arranged to form a segmented-in-series solid oxide fuel cell.7. The fuel cell system of claim 1, wherein said plurality ofelectrochemical cells further includes: an anode conductive layeradjoining said anode layer; and a cathode conductive layer adjoiningsaid cathode layer, wherein said interconnect is electrically coupledbetween said anode conductive layer and said cathode conductive layer.8. The fuel cell system of claim 7, further comprising a poroussubstrate adjoining one of said anode conductive layer and said cathodeconductive layer.
 9. The fuel cell system of claim 1, further comprisinga porous substrate adjoining one of said anode layer and said cathodelayer.
 10. The fuel cell system of claim 1, wherein said anode layer issubdivided into a plurality of anodes, each adjacent pair of anodesbeing separated by an anode gap extending in a predetermined direction;wherein said cathode layer is subdivided into a plurality of cathodes,each adjacent pair of cathodes being separated by a cathode gapextending in the predetermined direction; and wherein said primaryconductor defines a conduction path encased within said electrolytelayer and oriented along the predetermined direction.
 11. The fuel cellsystem of claim 1, wherein said electrolyte layer is formed of amaterial essentially impervious to diffusion therethrough of a fluidemployed by the fuel cell system.
 12. The fuel cell system of claim 1,further comprising an anode conductive layer adjoining said anode layer;and a cathode conductive layer adjoining said cathode layer, wherein atleast one of said auxiliary conductors is structured to form a chemicalbarrier against material migration between said primary conductor andone or both of said anode conductive layer and said cathode conductivelayer.
 13. A fuel cell system, comprising: an anode layer having aplurality of anode gaps and individual anodes; a cathode layer having aplurality of cathode gaps and individual cathodes; a solid oxideelectrolyte layer disposed between said anode layer and said cathodelayer, wherein said individual anodes, said individual cathodes and saidelectrolyte layer form a respective plurality of electrochemical cells;and an interconnect positioned between each electrochemical cell in eachpair of adjacent electrochemical cells, said interconnect beingstructured to conduct electrical current between electrochemical cells,and said interconnect including a conductive film embedded within saidelectrolyte layer.
 14. The fuel cell system of claim 13, saidelectrolyte layer including two electrolyte sub-layers, wherein saidconductive film is sandwiched between said two electrolyte sub-layers.15. The fuel cell system of claim 13, wherein said conductive film isstructured as a continuous strip.
 16. The fuel cell system of claim 13,wherein said conductive film is structured as a plurality of vias. 17.The fuel cell system of claim 13, wherein said anode layer is orientedalong first plane, said cathode layer is oriented along a second planesubstantially parallel to the first plane, and said electrolyte layer isoriented along a third plane substantially parallel to the first plane,wherein said conductive film extends in a direction substantiallyparallel to the first plane.
 18. A fuel cell system, comprising: anelectrolyte; a first electrochemical cell having a first anode, and afirst cathode spaced apart in a first direction from said first anode bysaid electrolyte, said electrolyte being structured to pass oxygen ionsin the first direction from said first cathode to said first anode; asecond electrochemical cell having a second anode, a second cathodespaced apart in the first direction from said second anode by saidelectrolyte, said electrolyte being structured to pass oxygen ions inthe first direction from said second cathode to said second anode; andan interconnect structured to conduct a flow of electrons from saidfirst anode to said second cathode, said interconnect including a blindprimary conductor disposed in said electrolyte and configured to conductthe flow of electrons in a second direction different from the firstdirection.
 19. The fuel cell system of claim 18, wherein the seconddirection is substantially perpendicular to the first direction.
 20. Thefuel cell system of claim 19, wherein said second anode is spaced apartfrom said first anode in a third direction substantially perpendicularto the first direction, wherein second direction is also substantiallyperpendicular to said third direction.
 21. The fuel cell system of claim18, wherein said interconnect further includes: a first blind auxiliaryconductor structured to conduct electrical power between said firstanode and said blind primary conductor; and a second blind auxiliaryconductor structured to conduct electrical power between said blindprimary conductor and said second cathode.
 22. The fuel cell system ofclaim 21, further comprising an anode conductive layer adjoining saidfirst anode; and a cathode conductive layer adjoining said secondcathode, wherein at least one of said first blind auxiliary conductorand said second blind auxiliary conductor is formed of a same materialas a corresponding one of said anode conductive layer and said cathodeconductive layer.
 23. The fuel cell system of claim 18, wherein saidblind primary conductor is formed of at least one of a precious metaland a precious metal alloy selected from the group consisting of Ag, Au,Pd, Pt, Ag—Pd, Ag—Au, Ag—Pt, Au—Pd, Au—Pt, Pt—Pd, Ag—Au—Pd, Ag—Au—Pt,and Ag—Au—Pd—Pt.
 24. The fuel cell system of claim 18, wherein saidblind primary conductor is formed of at least one of a precious metalcermet and a precious metal alloy cermet, wherein the precious metalcermet has a ceramic phase being at least one of yttria stabilizedzirconia (YSZ), scandia stabilized zirconia (ScSZ), Al₂O₃,LNF(LaNi_(x)Fe_(1-x)O₃), LSM(La_(1-x)Sr_(x)MnO₃), doped ceria, dopedstrontium titanate, doped yttrium chromites, and doped lanthanumchromite.
 25. The fuel cell system of claim 24, wherein said dopedlanthanum chromite is LSCM (La_(1-x)Sr_(x)Cr_(1-y)Mn_(y)O₃).
 26. Thefuel cell system of claim 25, wherein said LSCM isLa_(0.75)Sr_(0.25)Cr_(0.5)Mn_(0.5)O₃.
 27. The fuel cell system of claim18, wherein said blind primary conductor is a conductive-ceramic. 28.The fuel cell system of claim 27, wherein said conductive-ceramic is atleast one of LNF (LaNi_(x)Fe_(1-x)O₃), LSM (La_(1-x)Sr_(x)MnO₃), dopedstrontium titanate, doped yttrium chromites, and doped lanthanumchromite.
 29. The fuel cell system of claim 28, wherein said dopedlanthanum chromite includes LSCM (La_(1-x)Sr_(x)Cr_(1-y)Mn_(y)O₃). 30.The fuel cell system of claim 29, wherein said LSCM isLa_(0.75)Sr_(0.25)Cr_(0.5)Mn_(0.5)O₃.
 31. The fuel cell system of claim28, wherein said LSM is La_(0.75)Sr_(0.25)MnO₃.
 32. The fuel cell systemof claim 18, wherein said blind primary conductor is formed of at leastone of a Ni metal cermet and a Ni alloy cermet.
 33. The fuel cell systemof claim 32, wherein said at least one of said Ni metal cermet and saidNi alloy cermet has a ceramic phase being at least one of YSZ, alumina,ScSZ, doped ceria and TiO₂.
 34. A fuel cell system, comprising: asubstrate; a ceramic seal disposed on said substrate; an electrodeconductive layer disposed on said substrate; a first electrode of afirst electrochemical cell, wherein said first electrode is disposed onsaid electrode conductive layer; a second electrode of a secondelectrochemical cell; an electrolyte having a portion spaced apart fromsaid ceramic seal by a gap; and an interconnect having a conductordisposed within said gap between said ceramic seal and said portion ofsaid electrolyte, wherein said interconnect is operative to conduct freeelectrons between said first electrode and said second electrode. 35.The fuel cell system of claim 34, wherein said electrode conductivelayer abuts said ceramic seal.
 36. The fuel cell system of claim 34,wherein said interconnect defines a diffusion flow orifice structured tolimit diffusion of a reactant through said interconnect.
 37. The fuelcell system of claim 34, wherein said conductor is formed of at leastone of a precious metal and a precious metal alloy selected from thegroup consisting of Ag, Au, Pd, Pt, Ag—Pd, Ag—Au, Ag—Pt, Au—Pd, Au—Pt,Pt—Pd, Ag—Au—Pd, Ag—Au—Pt, and Ag—Au—Pd—Pt.
 38. The fuel cell system ofclaim 34, wherein said conductor is formed of at least one of a preciousmetal cermet and a precious metal alloy cermet, wherein said at leastone of said precious metal cermet and said precious metal alloy cermethas a ceramic phase being at least one of Al₂O₃, yttria stabilizedzirconia, scandia stabilized zirconia, doped ceria,LNF(LaNi_(x)Fe_(1-x)O₃), LSM(La_(1-x)Sr_(x)MnO₃), doped strontiumtitanates, doped yttrium chromites, and doped lanthanum chromite. 39.The fuel cell system of claim 38, wherein said doped lanthanum chromiteis LSCM (La_(1-x)Sr_(x)Cr_(1-y)Mn_(y)O₃).
 40. The fuel cell system ofclaim 34, wherein said conductor is a conductive-ceramic.
 41. The fuelcell system of claim 40, wherein said conductive-ceramic is at least oneof LNF (LaNi_(x)Fe_(1-x)O₃), LSM (La_(1-x)Sr_(x)MnO₃), doped strontiumtitanates, doped yttrium chromites, and doped lanthanum chromite. 42.The fuel cell system of claim 41, wherein said doped lanthanum chromiteincludes LSCM (La_(1-x)Sr_(x)Cr_(1-y)Mn_(y)O₃).
 43. The fuel cell systemof claim 34, wherein said conductor is formed of at least one of a Nimetal cermet and a Ni alloy cermet.
 44. The fuel cell system of claim43, wherein said at least one of said Ni metal cermet and said Ni alloycermet has a ceramic phase being at least one of yttria stabilizedzirconia, alumina, Scandia stabilized zirconia, doped ceria and TiO₂,doped strontium titanates, doped yttrium chromites, and doped lanthanumchromites.
 45. The fuel cell system of claim 34, wherein said conductoris a blind conductor.
 46. The fuel cell system of claim 35, wherein oneof said first electrode and said second electrode is an anode, furthercomprising an anode conductive film adjacent said anode and operative toconduct free electrons between said anode and said conductor.
 47. Thefuel cell system of claim 46, wherein said conductor is made from a samematerial as said anode conductive film.
 48. The fuel cell system ofclaim 46, wherein said conductor is an extension of said anodeconductive film.
 49. The fuel cell system of claim 34, furthercomprising a substrate, wherein said ceramic seal is adjacent to saidsubstrate.
 50. The fuel cell system of claim 49, wherein said ceramicseal is formed on said substrate.
 51. The fuel cell system of claim 34,wherein a material of said ceramic seal is yittria stabilized zirconia.52. The fuel cell system of claim 51, wherein said yittria stabilizedzirconia is 3YSZ.
 53. The fuel cell system of claim 34, wherein amaterial of said ceramic seal is scandia doped zirconia.
 54. The fuelcell system of claim 53, wherein said scandia doped zirconia is 4ScSZ.